Textile & Apparel
Textile & apparel: size/color matrix, CMT costing, PLM/tech-pack, subcontracting, export.
Challenges
- Different dye lots of the same colour get mixed, so shade differences show up in the order.
- Yarn is bought by the kilo but fabric is sold by the metre, so stock never reconciles between the two units.
- Roll numbers go unrecorded, so people search the warehouse to find how many metres are left on which roll.
- Greige fabric sent to the subcontractor does not match what comes back, so the waste calculation turns into an argument.
Workflows
From yarn to greige fabric
- Yarn purchases enter stock by the kilo with a lot number.
- A weaving or knitting production order is opened; the yarn consumption in the bill of materials is deducted from stock.
- The greige fabric produced is recorded with its roll number, metres and weight.
From dye lot to dispatch
- A dyeing and finishing lot is opened; each roll is linked to the lot it was dyed in.
- At lot exit a colour quality check is made; approved rolls are booked into finished goods stock.
- The order is filled from a single lot; the delivery note is issued with roll and metre detail.
Documents
- Weaving/knitting production order
- Dyeing and finishing lot slip
- Roll label and lot card
- Subcontract work order and waste report
Reports
- Production and waste report by dye lot
- Stock and remaining metres list by roll
- Metre–kilo dual unit stock reconciliation
- Quantity sent and returned by subcontract workshop
Metrics
- First-time approval rate of dye lots
- Metres obtained per kilogram
- Production waste rate
- Turnaround time from subcontractors
Compliance
- Turkish Revenue Administration e-Document scheme (e-invoice/e-delivery note)
- OEKO-TEX Standard 100 product safety
- Textile labelling and fibre composition regulations
Glossary
- Roll (piece)
- A stock unit tracked by lot number
- Dye lot
- A production order tracked as a colour lot
- Metre–kilo
- A dual unit stock item
- Subcontracting
- A subcontract work order issued to an external workshop
FAQ
Can I keep different lots of the same colour apart?
Yes — each dye lot is tracked as a separate lot, the order is filled from one lot only, and shade differences are prevented.
Can I track fabric in both metres and kilos?
Yes — the stock item carries dual units: receipts are posted in kilos, sales in metres, and the two units convert to each other.
Can I hold stock by roll number?
Yes — every roll is recorded with its own lot number, and the metres left on it plus its shelf location are visible instantly.
Can I track the fabric sent to subcontractors?
Yes — the subcontract work order compares quantity sent with quantity returned; the gap is reported as waste and posted to the workshop's account.
Can yarn consumption be deducted from the bill of materials?
Yes — the bill of materials defines yarn consumption per metre, and when the production order closes the usage is deducted from stock automatically.
