Carpet Manufacturing
Carpet Manufacturing: production orders and BOM, stock and warehouse, quality and reporting.
Challenges
- With so many design and size combinations, loom scheduling is done by hand and capacity sits idle.
- Yarn consumption is not calculated per design, so the true cost never emerges.
- Dye lots are not tracked, so shade differences reach the customer within the same order.
- Square-metre pricing and per-piece pricing get mixed up, so quotes and invoices do not match.
Workflows
From design to loom schedule
- Design, size and pile height are defined on the item card.
- The order is scheduled against loom and shift capacity.
- Yarn and colour requirements are derived from the design recipe.
From weaving to dispatch
- Weaving, washing and overlocking operations are tracked on the work order.
- The dye lot and the quality-control result are recorded.
- Goods are taken into stock in square metres and pieces, then shipped with a delivery note.
Documents
- Design and size item card
- Loom production plan
- Yarn recipe and dye lot record
- Quality control record and delivery note
Reports
- Loom utilisation and downtime report
- Yarn consumption by design
- Dye lot traceability report
- Production cost per square metre
Metrics
- Loom utilisation rate
- Yarn waste rate
- Second-grade rate
- Cost per square metre
Compliance
- Textile fibre composition labelling regulation
- REACH and dyestuff restrictions
- Wastewater and dyehouse discharge permit
Glossary
- Loom schedule
- A production schedule built on work-centre capacity
- Dye lot
- A stock movement carrying a lot number for traceability
- Pile height
- A technical specification field on the item card
- Second grade
- The stock class separated out by the quality-control result
Frequently Asked Questions
Can I plan against loom capacity?
Yes — every loom is a work centre; orders are scheduled against capacity and downtime is logged.
Can I see yarn cost by design?
Yes — the yarn and colour consumption from the design recipe is accumulated on the production order.
Can I prevent dye lot mismatches?
Yes — the lot number is tracked on every stock movement, so a single order can be allocated from one lot.
Can I use square-metre and per-piece prices together?
Yes — the conversion is defined on the item card, so quote and invoice use the same calculation.
Can I track second-grade products separately?
Yes — the quality-control result moves them into a separate stock class, sold under its own price list.