A women’s wear manufacturing company faced challenges in managing factory floor operations, including production scheduling, inventory management, and real-time monitoring of equipment. Manual systems resulted in inefficiencies, production delays, and inventory shortages. To address these issues, the company deployed Tilbury, an ERP system by iMayas, to optimize factory floor management.
Challenges Faced by the Textile Company:
Lack of Real-Time Production Data: Factory floor managers struggled to access real-time data on production, causing delays in decision-making and inefficiencies.
Inefficient Production Scheduling: Without an integrated system, production scheduling was manual, leading to misallocation of resources and delays.
Inventory Shortages and Overstocking: The company experienced frequent inventory discrepancies, either overstocking raw materials or facing shortages, which disrupted production.
Maintenance Issues: Equipment maintenance was reactive rather than proactive, causing unexpected downtime and delays.
Tilbury ERP Solution:
Real-Time Production Monitoring: Tilbury provided real-time visibility into production processes, allowing managers to track output, machine performance, and work-in-progress items directly from the factory floor. This ensured faster decision-making and problem-solving.
Automated Production Scheduling: The ERP system automated production scheduling, optimizing resource allocation based on demand forecasts, inventory levels, and machine availability. This reduced downtime and improved workflow efficiency.
Inventory Management: Tilbury integrated inventory management with production, ensuring that raw materials were automatically ordered based on current stock levels and production needs. This reduced the risk of shortages and overstocking, keeping production running smoothly.
Preventive Maintenance Scheduling: Tilbury helped the company implement a preventive maintenance system, allowing managers to schedule equipment maintenance based on machine usage and performance data. This reduced unexpected breakdowns and extended the lifespan of machinery.
Conclusion:
Tilbury ERP by iMayas transformed factory floor management for the textile manufacturing company, improving production efficiency, reducing inventory costs, and minimizing machine downtime. With real-time data and automated systems, the company saw significant improvements in operational performance, ultimately leading to higher productivity and profitability.
