Industry-specific solutions for footwear manufacturing and garment and textile production
The footwear and textile industries share a common specificity – production of a wide range of models with multiple sizes, colors and materials. The effectiveness of an ERP system in footwear manufacturing depends on how well it covers the business processes and reflects the specific characteristics of production. Each model requires strict cost norming by operation, accounting for scrap, yield and equipment setup costs, while the market demands short production lead times and intense price competition.
Footwear manufacturing
The process begins with specialists – designers, pattern engineers and process technologists. Production management starts as early as process engineering: building the structural specification (BOM) of the new product, integration with the CAD design system, and determining planned material costs.
A key characteristic is working with the size run – the specific set of sizes and quantities produced for each model. Each size of a model has its own identification number, which ensures precise traceability throughout the entire production cycle.
TECHNOCLASS® plans and manages footwear production while accounting for the size run, determines planned material costs factoring in scrap, yield, quality-control losses and equipment setup costs, and dispatches production according to conveyor parameters and the size-based assembly of lasts.
Production reporting happens in real time through shop-floor terminals of the TECHNOCLASS Terminal Data Collection System. An alternative solution for paperless management is the use of RFID cards and readers, which enables batch management of material assets, full traceability of material flow, and real-time accrual of piece-rate pay.
Key tasks in footwear manufacturing
Replicating new models and quickly configuring a new shoe model based on an existing one
Managing the process engineering of footwear production
Managing the norming of basic and auxiliary material consumption by operation
Determining planned material costs, factoring in scrap, yield and equipment setup costs
Maintaining the size run (size distribution) in orders and in production
Dispatching production according to conveyor parameters and the size-based assembly of lasts
Managing semi-finished goods by size
Planning orders and production according to the enterprise’s capacity
Knitwear production
A distinctive feature of knitwear production is the preparation of cut pieces and materials for sewing in batches of 10 units, and moving the bundles from one workstation to another – through to the final packaging station. As it moves, each batch is accompanied by an RFID card for identification.
An industrial terminal is installed at every workstation. When receiving a batch, the worker identifies themselves and the batch using the RFID cards, and logs the workstation and the start of the operation. If the workstation doesn’t match the routing, an error message appears on the screen.
This way the system guarantees that cut pieces are bundled from a single standard color, ensures the correct movement of batches through the routing sequence, tracks the actual duration of operations against standard times, and provides real-time data on labor input and piece-rate pay for every worker.
Key tasks in knitwear production
Managing batch production with 10 units per batch
Batch reporting with RFID identification of every batch
Tracking bundles between workstations through to packaging
Planning sewing operations by workstation and capacity
Guaranteed bundling of cut pieces from a single standard color
Position verification – alerts on mismatch between workstation and routing
Real-time data on labor input and piece-rate pay for workers
Operators in both types of production communicate with the management system through terminals of the TECHNOCLASS Terminal Data Collection System.
Discuss your project
Tell us about your production – the L-Class team will share experience from similar projects.