ERP Implementation at Weaving/ Textiles Sector
- Customer
- Qamar Fabrics Private Limited
- Project manager on the customer side
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- IT Provider
- Esthetics Solutions Pvt. Ltd.
- Year of project completion
- 2024
- Project timeline
- June, 2024 - October, 2024
- Project scope
- 350 man-hours
- Goals
- The goal of this project is to deploy a comprehensive Open-Source ERP Solution at a Weaving (Textiles) Mill, streamlining complex operational workflows and enhancing decision-making across departments. This ERP system addresses unique industry requirements, including in-house production, sub-contracting, and management of customer-provided items. It integrates financial management, procurement, supply chain, and sales operations into a unified platform, enabling real-time insights and improved collaboration. By automating and optimizing these critical areas, the solution aims to increase efficiency, reduce costs, and support seamless scalability for the mill’s evolving needs.
- Project Results
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The ERP implementation at Qamar Fabrics Pvt Ltd has yielded outstanding results, achieving 100% adoption of new technology across all departments. The transition from a manual, paper-based system to a fully integrated ERP solution has significantly streamlined operations, leading to enhanced productivity, improved data accuracy, and reduced operational costs. Real-time tracking of production, subcontracting, and inventory has eliminated bottlenecks, ensuring smoother workflows and timely order fulfillment. Additionally, the solution’s financial management capabilities have provided leadership with clear, data-driven insights, fostering better financial control and decision-making. Qamar Fabrics now benefits from a scalable, future-ready system that supports continuous growth and operational excellence.
The uniqueness of the project
The uniqueness of this project lies in transforming a textiles mill that has relied on manual paperwork for over 40 years into a digitally integrated operation using an Open-Source ERP Solution. Traditional ERP systems couldn’t meet their specific needs, especially given the complexities of in-house production, sub-contracting, and handling customer-provided items. This solution is uniquely tailored to address these intricacies, encompassing end-to-end management of financials, procurement, supply chain, and sales within one platform. It’s a pioneering shift that brings real-time visibility, accuracy, and efficiency to processes that were previously fragmented and labor-intensive, setting a new standard for ERP capabilities in the textiles industry.- Used software
- ERPNext based on Frappe Framework deployed on MS Azure Cloud.
- Difficulty of implementation
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The implementation of the ERP solution at Qamar Fabrics Pvt Ltd presented several significant challenges, requiring a careful approach and meticulous planning. One major hurdle was change management, as employees accustomed to manual processes for decades needed comprehensive training and support to adapt to the new system. Additionally, the lack of historical digital data and absence of standardized practices added complexity, necessitating data creation, validation, and process alignment from scratch.
The mill’s unique process knowledge posed further challenges, especially with tracking customer-provided items, handling in-house and subcontracted production, and managing multi-stage manufacturing with multiple material conversions. Each conversion involved complex costing structures, making accurate tracking essential to maintain profitability. These intricacies required tailored solutions and careful configuration to ensure every stage was properly recorded and reported. Despite these complexities, the project was a success, achieving full adoption through focused collaboration, customization, and hands-on support for the Qamar Fabrics team.
- Project Description
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This project involves implementing a tailored Open-Source ERP Solution at a Weaving (Textiles) Mill that has relied on manual, paper-based processes for over 40 years. The primary objective is to digitally transform and integrate all core functions of the mill to enhance operational efficiency, accuracy, and scalability, addressing industry-specific challenges that traditional ERP systems failed to meet.
The ERP solution is designed to support complex operational scenarios, including:
In-House Production Management: Streamlining production processes by enabling real-time tracking of each production stage, from raw materials to finished goods. This module ensures accurate data on inventory, production schedules, and labor allocation, improving both time management and resource utilization.
Sub-Contracting Management: Managing subcontracted work with full visibility into outsourced processes, ensuring quality control and timeline adherence. The ERP solution tracks materials sent out for processing and monitors subcontractor progress and costs, enhancing accountability and improving vendor relationships.
Customer-Provided Items: This feature allows tracking of materials provided by clients, supporting the weaving mill’s unique requirement of managing both customer-owned and mill-owned inventory. The solution keeps detailed records of these items, from receipt to final product delivery, ensuring transparency and easy reconciliation.
Financial Management: Fully integrated financial tools streamline budgeting, cost tracking, and accounting functions. The ERP automates complex accounting tasks and provides accurate financial statements, enabling leadership to make data-driven financial decisions that directly impact profitability.
Procurement and Supply Chain Optimization: The system automates procurement workflows and optimizes inventory management, offering a clear view of stock levels, reorder points, and supplier performance. With automated purchasing, supplier management, and contract tracking, the mill can ensure timely and cost-effective sourcing of materials.
Sales and Order Management: Automating order processing, customer invoicing, and delivery scheduling, this module enables efficient tracking of sales orders and customer requirements. The ERP supports multi-channel sales operations and provides real-time insights into sales trends, improving customer service and responsiveness.
By consolidating all functions into a single, integrated platform, the ERP solution delivers real-time insights and seamless information flow across departments. This digital overhaul enables accurate tracking of production costs, effective resource allocation, and improved compliance through centralized data management.
The ERP deployment represents a monumental shift for the client, offering an unprecedented level of operational control and scalability. Designed to grow alongside the mill’s expanding needs, the solution future-proofs the client’s business, ensuring agility in a highly competitive industry.
- Project geography
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The ERP implementation project for Qamar Fabrics Pvt Ltd is geographically focused in Lahore, Pakistan, the heart of the country's textile industry. With over 40 years of legacy in textiles, Qamar Fabrics has established itself as a renowned player in the region, known for high-quality weaving and fabric production. The ERP solution deployed is designed to support not only the operational complexities within their Lahore facility but also to provide scalability for potential expansion. This project strengthens Qamar Fabrics’ competitive edge within Lahore’s vibrant textiles sector by introducing a streamlined, data-driven approach to production, procurement, inventory, and sales management. The ERP's localised configuration also considers the specific business practices and regulatory requirements in Pakistan, ensuring a seamless alignment with regional standards while preparing Qamar Fabrics for future growth in both national and international markets.