Yarn Production System (MRP)

About the System

Developed primarily for yarn manufacturers, the flexible architecture of this system also covers other manufacturing sectors. It is a genuine MRP software solution that tracks all production stages in a digital environment — from raw material intake right through to finished product sales. Customer-focused by principle, our company has successfully delivered numerous MRP projects that lighten the control and monitoring burden within manufacturing operations.

Barcode System & Online Scale Integration

One of the most important features of this barcode-enabled system is its online communication with weighing scales. Users do not need to enter weighing data manually — incorrect weight entries are eliminated and both weighing speed and barcoding throughput increase significantly. The system automatically performs the stock entry at the point of weighing, removing the need for a separate data-entry step. At the same time, the barcode label for each product is generated automatically. As each product is weighed, the recipe's raw materials are automatically deducted from stock — including waste ratios — giving you a real-time, error-free view of current raw material warehouse levels.

While weighing, the system simultaneously prints the barcode and records each product by its barcode number (serial number) and stock code. Serial numbers are assigned by the system according to a defined logic and are never duplicated, meaning every weighed unit (pallet, sack, box, etc.) receives a unique identity.

Sales Dispatch & Stock Operations

All product sales and dispatches are handled through automatic online barcode-reading hand terminals. Because the terminal software can process simultaneous dispatch to multiple customers in a single session, time lost during the shipping process is kept to a minimum. The strict validation logic built into the hand terminal software prevents the operator from dispatching any product that has not been assigned a dispatch order, eliminating the risk of incorrect shipments entirely.

Order Operations

Order quantities entered into the system are automatically updated as finished goods are dispatched. This gives you accurate, real-time visibility into outstanding order balances at all times. For planning purposes, the system calculates the required production quantities based on the current open orders.

Quality Control

The system accommodates various interfaces to match the equipment and instruments in a company's quality control department. Quality measurement values for every product that passes through quality control are recorded against the date and machine. Specifications with nominal, upper, and lower tolerance values can be defined for each product to establish the acceptable quality level. Compliance of all measurements with defined tolerances can be monitored through a variety of graphical displays.

User Permissions

The system includes a detailed user authorisation module. Every module, report, and button within the application can be permission-controlled at the individual user level, ensuring that each user only accesses the areas relevant to their role.

System Architecture

The stock module is designed in a parametric structure so it can be easily adapted to different industry requirements. Stock card definitions are created by combining pre-defined parameters. Weighing and labelling are fully automated and free of human error. Serial number tracking lets you trace any product down to its smallest individual unit, and the complete movement history of any sack — including production date, warehouse, client, group, variety, and cone type — remains accessible even years later.

All data grids displayed on screen can be exported directly to Microsoft Excel. Column headers support custom filtering and grouping so you can generate a wide variety of tailored reports.