Footwear
Footwear: size/dimension series, last/grading PLM, production, dealer distribution.
Challenges
- The size run is held as a single item, so nobody knows how many pairs are left in each size.
- Upper making, lasting and finishing are not tracked separately, so the stage an order sits at is invisible.
- Cost per pair is never calculated, so rises in leather, sole and labour never reach the price list.
- Cut leather sent to the upper-making subcontractor does not match the uppers returned, so the reckoning happens far too late.
Workflows
From last to size run
- The model's last is defined; the 36-45 size run is generated through the variant matrix.
- The model's bill of materials holds leather, sole, lining and trim consumption per size.
- The model is linked to a season collection and a production order is opened.
From upper to finished pair
- Cut leather goes out to the upper maker on a subcontract work order; the uppers returned are recorded.
- Sole lasting and finishing stages are closed in sequence on the production order.
- Pairs that pass quality control are booked into stock by size and attached to the delivery note.
Documents
- Model and last record
- Production order with size run
- Subcontract upper-making work order
- Delivery note itemised by pairs
Reports
- Stock and order fulfilment by size
- Production status by stage (upper/lasting/finishing)
- Cost breakdown per pair
- Sent vs. returned reconciliation for upper-making subcontractors
Metrics
- Cost per pair
- Size run fill rate
- Transition time between stages
- Second-quality (reject) rate
Compliance
- Turkish Revenue Administration e-Document scheme (e-invoice/e-delivery note)
- Footwear material labelling regulations
- REACH restrictions on chemical substances
Glossary
- Last
- The model record that defines the size run
- Upper
- A semi-finished item tracked through a subcontract work order
- Size run
- A 36-45 variant matrix
- Pair
- The unit for stock and costing
FAQ
Can I keep separate stock by size?
Yes — the 36-45 run is generated by the variant matrix; each size is tracked as its own stock item and counted separately.
Can I see which stage an order is at?
Yes — upper making, lasting and finishing are separate stages on the production order, and the closed stage plus the waiting quantity are visible at any moment.
Can I calculate cost per pair?
Yes — leather, sole and trim from the bill of materials plus labour are allocated per pair, and size differences flow into the cost.
Can I track the upper-making subcontractor?
Yes — the subcontract work order compares the leather issued with the uppers returned, and the gap is posted as waste to the subcontractor's account.
Can I report by season collection?
Yes — models are grouped by a season tag, and pairs sold and pairs left are reported together per collection.
