Manufacturing Solution for Textile Industry

Hello Everyone,
Can anyone share his/her experience of manufacturing solution for a textile industry. A Towel manufacturing company is interested in using Oracle's Standard Solution for manufacturing.
There manufacturing process starts from Weaving, they do not manufacture Yarn and the end product is Towel of different sizes, colours and grades.
The main question is Which product family should be implemented Discrete or Process and which modules of that family?
Thanks in advance.
Israr Ashfaque

Hi
You need to use a seperate Nomenclature for all the Finished products, which are uniquely identified. This is possible with Oracle Inventory module.
Like 9999999colxyz
Numeric represent year/mont/date (if reqd)
Col represents Actual color of thread/wool
xyz represents Any other attribute of the thread/wool
So you can use this kind of Item codification for better tracing and marketing.
Thanks
Raj
NTT Data

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Need BOM related solution for Textile Industry (Weaving proces)

HIi,
Made to Order Strategy:
Every times customer sends the specification of product. Specification format as given below:
Ex. 80x100/154x80*3-118u201D 4/1 Twill
Details of specifications:
     80: Count of EPI (Ends Per Inch)
     100: Count of PPI (Picks Per Inch)
     154: EPI
     80: PPI
     3: Insertation
     118u201D u2013 Width in Inch
     4/1 Twill : Design of Fabric
Operations Details:
1 Warping
2. Sizing
3. Weaving
4. Quality Inspection
5. Packing
As Is Business Process:
There are mainly four production lines viz. Warping, Sizing, Weaving and Quality Inspection. For all the production lines the individual machine work centers will be as listed below with brief description:
1.     Sectional Warping:
A kind of Warping specially used to prepare fabrics for shirting. In sectional warping dyed yarns are used to prepare warping beam. The end constraint of sectional warping is 720 ends at a time. The actual capacity of Sectional warping is 800 MTR/min. This activity is job work for DEESAN group.
2.     Direct warping:
Direct warping process is used to prepare warping beam. The end constraint of warping is 1088 ends per beam. Machine width of the beam in 2200 mm, speed of warping varying from 300 MTR to 1200 MTR per minute depending upon the construction required. It has backup procedure for next round. Uploading speed   for single yarn is 8 yarn / min / person.
3.      Sizing:
Sizing process is used to prepare specific number of EPI/ beam as per the requirement of construction. A calculated no of warp beam used to prepare a single sizing beam. Speed of sizing 45 to 55 MTR / minute depending on the requirement of fabric.
4.     Preparation of Drawing:
This process is used to preparation of new drawing for the loom machine. Drawing includes frame & reed. It will take 12 hr for 2 persons to prepare a single drawing i.e. 8000 ends per shift. This activity given as job work to some group of people.
5.     Weaving:
Two types of weaving machines used are CAM and DOBBY. Fabric to fabric PPI is varying, the capacity of loom machine depends upon the PPI so the capacity of loom machines varying with the type of fabric. CAM is used specially for plain fabrics.
6.     Quality Inspection:
The beams of fabrics coming from looming machine are inspected on Inspection machine. 100% fabrics are inspected on QA machine for further grading, which is then bifurcated in Export, Local and chindi type.
7.     Rolling:
Rolling machine is used for rolling of inspected fabric on card board rolls according to the quality of fabric. A roll contain of maximum 350 MTR of fabric. Which are then packed with LDPE followed by HDPE with appropriate coding on rolls.
Material Requirement:
For ex. 80x100/154x90*3-118u201D 4/1 Twill
Order Qty.: 20000 M
Currently they are using single level BOM.
Formulas for calculate raw material requirements as given below:
Warp wt / mtr = (EPIWidthCrimp) /(1693*Count of EPI)
          = (154 * 118 * 1.025)/(1693 * 80)
          = 0.137524
          = 0.138 Kg/Mtr
Weft wt / mtr = (PPIInsertationWidth * Crimp) /(1693*Count of PPI)
          = (9031181.025)/(1693100)
          = 0.192891
          = 0.193 Kg/Mtr
Total Qty req:
Warp = 0.138 * 20000 + add 5% loss
     = 2898 KG
Weft = 0.193 * 20000 + add 4% loss
     = 4014 KG
Packaging material requirement :
1. Paper tube = Total order qty / approximately for 300 m 1 paper tube required + 5% loss
          = 20000 / 300 *1.05
          = 70
2. HDPE sheet = No. of paper tube * 0.4 KG
      = 70 * 0.4
     = 28 KG
3. LDPE sheet = No. of paper tubes * 0.15 KG
          = 70 * 0.15
          = 10.5 KG
Chemical consumption in terms of yarn on KG basis. Its combination of 4-6 chemicals depends on construction to construction also material availability.
Note: We will consume chemicals against cost center.
Production planning at execution time:
Sizing and warping calculation:
1.     Sizing :
EPI per inch = 154
On loom will be = 154 * 1.025
           = 157.85
Total no of ends for 118u201D width = 157.85 * 118
                    = 18626
Add one more ends per 1000 ends = 18626 / 1000
                    = 19 ends
Total no of ends = 18626 + 19
          = 18645 for sizing
Warping :
Warping m/c capacity of output is 1088 Ends per set/beam.
Speed of machine 300-1200 MPM.
So for sizing we need 18645 ends. Now we want to calculate no warp set required for sizing & no. of ends per warp set.
Ends required per set = 18645 / 18 = 1036
     i.e. 18 * 1036 = 1 Sizing set
We need total yarn on KG basis
Issue related to BOM:
1.     How We can feet below 2 issues in BOM
a.     we want to calculate RM(Yarn) material requirement in Unit of u201CENDu201D
NOTE: Procurement of Raw material Unit- KG as well as it depends no. of ends required for warp set / beam. i.e. its multiple of yarn cone required for 1 warp set.
As per Bom of Raw Martial Unit- Ends (EA)
b.     Also we want to calculate no of warp set required for sizing and no of ends required for warping process.

Hi Pankaj,
Hope you might have completed the project for Textile industry. I need to know implementation in Textile and some specific process. If you can share some documentation for Textile industry would be very helpful for me. My id k.anamika06 at gmail
Thanks a lot
Anamika

Guest Wifi Solution for Hotel Industry

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B)MemberInternet (In house Guest - User Charge after consuming 500MB data)
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Duplicate Post:
https://supportforums.cisco.com/thread/2267649?tstart=0

Designing Work Center & Assigning in Routing For Textile Industry

Dear All
There are around 20 Looms in weaving.As per clients requirement to map indvidual Loom efficiency each loom is considered as indvidual work center.In routing its possible to assign only one work center.
Kindly suggest me how to map this scenerio.The client requires machine wise output.Should i raise 20 Production orders for indvidual Work centers.
Regards
Jay

hi,
i am sending the information about
Maintaining Individual Capacities in the workcenter,
Prerequisites
Individual capacities are used in capacity planning for more detailed resource planning. For instance, you can divide a machine capacity into several individual machines and maintain an available capacity for each machine. Capacity requirements can then be distributed among the individual capacities. If you do not maintain an available capacity for an individual capacity, it is calculated from the operating time of the capacity to which the individual capacity has been assigned.
Individual capacities have the same capacity categories as the capacities to which they are assigned.
In order to be able to create individual capacities the CapCatPers indicator for the capacity category must not be set in Customizing.
Procedure
Assigning Individual Capacities
On the header screen choose Goto ® Individual capacities.
The Assignments to Individual Capacities screen appears.
Define the individual capacities.
Maintaining Available Capacities for Individual Capacities
In the Assignments to Individual Capacities screen place the cursor on the individual capacity whose available capacity you want to maintain.
If the Maintnd indicator has been set, then an available capacity has been maintained for this individual capacity.
thanks
sbabu

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We have implemented MySAP ECC 6.00 in our company. Our company produces BOPP Film. We have implemented 6 modules FI,CO,PP,MM,SD and QM. In PP modules we stuck because of width. I want to ask whether there is any industry specific solution for Process Industry?
Sudhir

Hi Sandeep,
Thanks for your prompt reply.
I will explain you in detail.
Our Company was started in 1980 to manufacture Bi-axially Oriented Polypropylene Films (BOPP) for the first time in India. Since inception we have maintained market leadership in the Indian market and also Continues to be largest BOPP film exporter from the Country. .
In 1996 we have implemented AVALON erp. The implementor was TCS Hyderabad. Presently also it is running very fine but due to technical cnstraints, we decided to switch over to SAP.
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As far as our process is concerned first stage to produce a JUMBO roll. The width may be 1000 mm. Further these Jumbo rolls are slitted as per requirement from customer. Here the width part plays a major roll. The requirement from customer is in any width right from 64 mm to 500 MM. Let us say our product code is xyz with various width. Our main requirement is widthwise stock and widthwise costing. We do not want to incorporate the width in itemcode. How can this problem will be solved?
Waiting for a feseable solution.
Thanks Sudhir

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Hi All,
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Scenario 1.
My client gives warehouses on rent to their customers to store their Inventory. My client provides the Labour required for that particular warehouse and transportation if required.
Scenario 2. (3PLS) (Third Party Logistics Services)
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Edited by: shashi mantripragada on Jun 29, 2009 12:24 PM

Hi,
We can have work solution for this service process mapping.
Any work around solution in B1 there has to be financial implication on that. So we have to be very careful on defining GL Account Determination and its financial implication.
And that will be accounted in our books of accounts.
Here we will receive only charges out of from the services, what we have to given the service to them, for this we will do service invoice (AR Service Invoice) to account those charges.
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Charges should be accounted through service invoices and inventory tracking should go through goods issue and goods receipt document (Inventory Transaction in Inventory Module) .
Please consult a Finance person before going to do that these configurations. But it is possible in B1.
Thanks and Regards,
Senthil Maruthappan.
Team Work Never Fails.

Cost solution for new energy insdustry like wind & sun power

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The customer focuses on wind & sun power and fuel cell.
Can you share any documents for that?
Thanks...........

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Textile Industry -Material type

HI Friends , For textile industry which material type we have to use

Hi,
In textile industry there lot of material types
For finished goods it is Fert
Semi-finishe goods its Halb
raw material it is Roh
Hope this will help you
reward me if possible
Thanks
Reagards
R.Manoj

Industry Solution for High Tech Manufacturing - how to activate?

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I'm Basis consultant installing ECC 6.0 at a client site. The client company has purchased a package from SAP that includes the " SAP Industry Solution for High Tech Manufacturing ."
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If not part of ECC-DIMP, does this purchase refer to Best Practices for High Tech, which does require additional software. In this case I believe I will need to install the Baseline package for BP, then the specific BP for High Tech.
Follow-up question:
1. Could either of these be installed later, or would that break existing new configuration?
Thanks in advance for your help!
Glen

Hi Glen, I just saw your posting from two months back and wondered if you had gotten your answer, and if by saying that the client had purchased a package from SAP that includes the " SAP Industry Solution for High Tech Manufacturing ", did they mean SAP Best Practices for High Tech?
Please let us know if you have any questions,
Marian

SAP industrial solution for Mining (IS-Mining)

Dear Experts,
I believe that SAP has industrial solution for Mining (IS-Mining). Do they have BW analytics / Reports for the IS-Mining ?
Appreciate an early response.
Thnx n Rgrds
Mohan
Edited by: Mohan Kumar on Nov 4, 2008 7:39 AM
Edited by: Siegfried Szameitat on Nov 5, 2008 10:12 AM
Edited by: Mohan Kumar on Nov 6, 2008 1:26 PM
Edited by: Mohan Kumar on Nov 6, 2008 1:26 PM

Can some one pls reply on this.
Edited by: Mohan Kumar on Nov 17, 2008 6:05 AM

Which interface for documents for process manufacturing for chem industry?

Hi,
My partner is looking for a technical contact who could help him in finding the right integration to manage technical documentation for process manufacturing in the chemical industry.
Not sure if this is the right forum but any advice would be appreciated.
Thanks, Seher

Hello Seher,
as there are several ways in SAP to manage documents I need som emore information to give you a reliable answer:
What is the process you want to support, what do you want to do with the documents?
Do these technical documents have a lifecycle?
What are the requirements to "manage technical documentation"?
What do you mean with "integration"? E.g.: Do you want to link a document to an SAP object?
Where are the documents today, file server?
Best regards,
Michael

How can a company sell a Times Capsule appliance as a solution for backup and die for this manufacturing fault? And with that Apple? nothing, or technical assistance. Of a sledgehammer, open the device and attempt to recover your files by force!???

How can a company sell a Times Capsule appliance as a solution for backup and die for this manufacturing fault? And with that Apple? nothing, or technical assistance in Brasil. Of a sledgehammer, open the device and attempt to recover your files by force!???

Heat up the bottom rubber mat with a hairdryer for 5-10 minutes to loosen the adhesive, then pull the rubber mat away from the bottom metal plate carefully.
Then use a screwdriver to remove the 10-12 screws to open up the case.

What is the Best practice for ceramic industry?

Dear All;
i would like to ask two questions:
1- which manufacturing category (process or discrete) fit ceramic industry?
2- what is the Best practice for ceramic industry?
please note from the below link
[https://websmp103.sap-ag.de/~form/sapnet?_FRAME=CONTAINER&_OBJECT=011000358700000409682008E ]
i recognized that ceramic industry is under category called building material which in turn under mill product and mining
but there is no best practices for building material or even mill product and only fabricated meta and mining best practices is available.
thanks in advance

Hi,
I understand that you refer to production of ceramic tiles. The solution for PP was process, with these setps: raw materials preparation (glazes and frits), dry pressing (I don't know extrusion process), glazing, firing (single fire), sorting and packing. In Spain, usually are All-in-one solutions (R/3 o ECC solutions). Perhaps the production of decors have fast firing and additional processes.
In my opinion, the curiosity is in batch determination in SD, that you must determine in sales order because builders want that the order will be homogeneus in tone and caliber, and he/she can split the order in diferents deliveries. You must think that batch is tone (diferents colours in firing and so on) and in caliber.
I hope this helps you
Regards,
Eduardo

SAP Solution for Mini steel plant with DRI Process

Dear all,
I am a metallurgist who spent couple of years in steel and process Industry and then moved to IT Consulting as SAP consultant / business analyst mainly working in the area of solution designing.
Here i will like to describe SAP solution for Mini steel plant with DRI proces.
u201CManufacture Productsu201D Description
The series of operations performed upon material to convert it from the raw material or a semifinished state to a state of further completion. This includes the establishment and maintenance of a CAPEX plan, the planning, scheduling and execution of production activities, the dispositioning of produced goods, the maintenance of production data, the monitoring of production performance and the implementation of engineering changes.
u201CManufacture Productsu201D Objectives
M-010
Compile 3-year CAPEX Budget     Establish the overall manufacturing goals and metrics that the organization will use to measure performance and progress towards objectives. These goals should be consistent with overall organizational strategy/value propositions. Develop long-term goals for production capabilities and manufacturing. These goals should align with the overall goals and objectives of the organization.
M-050
Perform Long Range Production Planning     u201CBudgetingu201D. Long range planning of production quantities based on planned available capacities and known or estimated customer demands. This process may include planning for different capacity and/or demand scenarios. Approved capital expenditures from the 3-year CAPEX budget may influence the budget. Range and frequency for budgeting is yearly.
M-060
Perform Medium Range Production Planning     Medium range planning of production quantities based on planned available capacities and known or estimated customer demands. This process may include planning for different capacity and/or demand scenarios. Range and frequency for planning is quarterly.
M-070
Perform Short Range Production Planning     Short term planning of production quantities based on capacities and demands as previously planned in the longer terms, actual customer demand and actual capacities. The result from short range production planning will run into the operational plan for the current and following days. Range and frequency for planning is monthly.
M-080
Schedule Production     This sub-process enables detailed scheduling by resources over the planning horizon. Planned orders that fulfill demands (Stock Transfer Requisitions, Sales Forecasts and Customer Orders defined by due-dates and due-quantities) come from the short range plan. This results in a feasible schedule, optimizing utilization of the production resources. It is based on production process constraints as well as labor resources in order to minimize production costs and also taking into account constraining raw materials availability.
M-090
Execute MRP     The purpose of this sub-process is to generate a Materials Requirements Plan (MRP) for all materials, which are produced or purchased. The MRP process involves looking at current material inventory, planned inbound material deliveries, requirements, lead times and stock levels to generate a detailed plan for future material requirements. The materials requirements will be generated with respect to the three planning horizons, short-term, medium-term, and long term. If an over stock of raw materials occurs as a result of a planning change production and marketing personnel will be informed. This would allow for the cancellations of any unneeded shipments.
M-100
Perform Setup / Changeover     Perform set-up and changeover activities on production equipment as necessary, to prepare for the production of specific materials/grades. Set-up and changeover activities will enable the production equipment to perform operations on materials, as per the specifications called out on the production order. Ensure time is allocated for first off inspection requirements after changeover.
M-110
Execute Production     Insure that the production plan is met by converting raw materials and component supplies into finished and semi-finished products. Batch/lot documentation will be created for individual production orders to provide traceability throughout the process. Each step of the production process is continuously monitored to identify mechanical, quality, and productivity issues and suggest solutions when problems arise. Data collection for performance and financial reporting enables management to take immediate action on manufacturing processes as well as conduct historical analysis.
M-120
Perform Quality Management     Quality management refers to the entire supply chain process. Process activities are related to the evaluation and inspection of key characteristics of semi-finished and finished materials. These evaluations are recorded and acted on based on the results. Report/manage internal quality problems or issues. Install and manage quality control systems to insure product quality. For supplier or subcontractor based issues this data should be used as a performance measure during the vendor evaluation process.
M-130
Manage Product Disposition     This process ensures those semi-finished and finished products that do not meet quality requirements, are prevented from being used and distributed in good finished product to customer, or released for the next step of the production process. A semi finished product is any material that needs to have another operation on line before being shipped to the customer. Finished goods are defined as any material that can be shipped to a customer; in house produced finished goods, subcontracted materials and trading goods. The information required to make decisions regarding disposition comes from the Quality Management system of each production facility. The first step ensures that raw material and returnable goods are dealt with in another subprocess. The reason for the goods not meeting quality standards is recorded along with the results of any investigation to find the cause of the fault. Information is sent to all other parties who need to know: order fulfillment, inventory management and shipping. The process ensures that the most appropriate action is taken to either dispose of, or rework the goods. Disposal or rework may be either through the original materials supplier or subcontractor, or Mittal Steel Point Lisas.
M-140
Maintain Product Related Data     u201CMaterial Master Maintenanceu201D. The Sub-Process 'Maintain Product Related Data' is the list of activities that identify the steps and decision points related to the request for and performance of additions, changes, and deletions to the Material Master file or files. This sub-process begins when a need to create, change or delete a material is identified and ends when the request is either actioned or refused. The sub-process is intended to cover all material types, including finished goods, raw materials, bills of materials, equipment and service, POS, Sundry Items etc. In fact, any product which the company wishes to inventory or purchase. A number of key strategic decisions, including a clear definition of when we issue a new material, will affect this sub-process.
M-150
Maintain Production Related Data     u201CMaster Data Maintenanceu201D. This subprocess identifies the activities related to requesting changes or additions to production related master data. Once a need for master data maintenance is identified, a request is submitted for approval. Data defining production capacities and performance standards (e.g. line efficiencies, material yields, etc.) require Corporate level approval prior to maintenance. Other data that is more specific to internal planning functions are maintained at the plant level. Maintenance requests are returned to the originator whether the request is approved or not to improve communication throughout the system. This subprocess may be triggered by: annual operations budgeting process process/production equipment upgrade or replacement change in facility work schedule (i.e. planned hours or days) change in personnel required to operate process/production equipment new products, formulations, or packaging.
M-160
Operations Execution Reporting     Gather manufacturing information at various points in the production process. Prepare management reports both at the detailed level for plant management and summary level for senior operations management. Reports will be available on-demand and will include - volume, efficiencies (mechanical, line, and labor), yields, downtime, asset utilization, environmental, safety, quality, and financial data. A major goal of this sub-process is to define a consistent method of calculating operations metrics. Some plants will use line information systems and PCSs to collect information. Not all plants are equipped with these systems and the where they do exist, the level of sophistication varies.
M-170
Manage Process Reliability     Optimize capacity by reducing process downtime and ensuring compliance to quality expectations by the reduction of rejects. Install tracking systems to measure line time utilization, quality results, process settings. Conduct root cause analysis, and use the data to develop and implement improved operating procedures.

Thank you for your prompt response. I'm assuming you are still proposing to use Sales order -> purchase order -> invoice verification -> Customer billing process flow. Is that correct?

Textile Industry (Weaving Operation)

Hi,
In textile industry we got order. Itu2019s totally MTO strategy. Customer required as per his specification like 40x60/124x86*2-110u201D-4/1 Twill.
There is two types of planning process (BOM)
1. Just total yarn required for order.
2. No of ends required (as per specification) for fabric. For fabric manufacturing we had operations warping, sizing, & weaving. For sizing we need no. of warp sets. For warp set we need no. ends.
Requirement: From BOM we can calculate total yarn (Kg) req. for production as well as no ends for sizing, no of ends for warping, and last wt of single yarn (Kg)
Thanks & Regards,
Dhamane

closed

Manufacturing Solution for Textile Industry

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