Smaac Net Solutions Pvt. ltd.

Smaac-Tex

Smaac-Tex ERP is meant for Knitting & Processing of Knitted Fabrics. 25 years of working experience in knitting, processing & garmenting gave birth to this software.  Smaac-Tex is not an ordinary software or ERP but years of experience and knowledge is built into it. It is software developed by industry persons as per the industry needs. This software has evolved in last 10 years and seen multiple facets of the industry. Now Smaac Net Solutions is presenting this for the industry in its new avatar.  Reliability and ruggedness of ERP comes from its dot net platform & MSSQL. In last 10 years employees through their valuable inputs & feedback enriched it.  All types of different functionalities are added into this ERP in these years. Mr. Sushil Gupta who is M.Tech. from IIT Delhi and founder director of Richa has been brain behind this. 

Evolution of Smaac-Tex

2004, we at Process house spent tens of lac rupees for software for Processing but nothing worked unless Mr. Gupta decided to develop software themselve. It started with a small lot register program using MS-Access & SQL. From there started the journey of development of this ERP. It became a full-fledged ERP till 2014 when it was realized the need for change. Marketing persons use to underquote and management felt helpless to exercise control. This was resulting into loss to the industry when processing rates were quoted lower than cost prices. I decided to bring a change to this where I took with me industry captains but it was challenge for me to control things internally. We needed to check our marketing team while quoting their prices. In this backdrop, we developed Work Contract Order (WCO) program which checked all the revenue leakages. This gave a big boost to our revenues at Richa. Slowly it became such an important tool that everything started revolving around it. Minimum rates of different processes including weight losses were controlled here. Dyeing shades were linked with lab recipes to check if the rates are correctly quoted. There was a time when dyes prices were out of bounds and we needed to quote our prices based on future rates of Dyes. Here we incorporated features in ERP to avoid wrong quotes. I remember one instance when we had to service 100 tons of Black shade for one of my customer at old rates as marketing person was unaware of the changes in cost of dyes.

2011, we use to maintain XL sheets for reporting daily production and processing head use to hide some vitals facts in those reports. I always have doubt on the veracity of those reports. On this back drop we built daily production reports which showed us clear picture of each lot, average loading, Equivalent Dyeing, Re-processing, cost of production, etc. It gave a different dimension in making system transparent. Then came to notice pilferage of dyes and chemicals. We normally charge our client based on lab recipe but at times there are huge pilferages in a dye house. Dyeing managers use to hide errors and shortcomings which normally result into pilferages. We developed program in ERP to report such pilferages which gave huge savings. We need to check if we are dispensing the same quantity we want to dispense. This also helped in improving quality.

2015, we use to receive huge debits from clients on account of delays (Air freight), Fabric reconciliations, fabric shortages, dyeing defects, etc. We first developed program for these debit notes so that we can analyze these debits. Than we worked in ERP so that we can attack and reduce these debits. Smaac-Tex now reports days we are taking in different sections and total turnaround time for each WCO, lot, client or month. This brought to the notice bottlenecks we have in the processing. Now transparency of fabrics at different stages helped us in avoiding those debits.

2015, We gained immense knowledge in handling inventory and other processes while developing ERP for our PEB division. Based on the inputs from different departments we brought in major software programming from PEB software and merged in Textile ERP. This strengthened and gave new dimension to inventory handling. Indenting, Purchase Orders, Material Requisition Notes, Reports, etc. got major boost with this.

2016, We revamped knitting module. We decided to dump old VB6 code for knitting module and developed altogether new code in dot net with new functionalities. Major focus was ease of working and reduced paper work. Entire structure was realigned and it was big success as all the users and management was very happy with its outcome. A new search tool was introduced for all the fabrics we us produced in the past.

2016, Still xl sheets were used for the planning of dyeing. Numerous software developments for dyeing planning failed in the past due to numerous reasons. We needed to plan for lots where fabric is yet to be received. We need to account for lots (partial/full) coming for Reprocess.  At times, lots are loaded without planning. With continuous efforts and employees feedback we could develop a stable and dynamic dyeing planning module. It was a major breakthrough after so many years.

2016, we were having two parts or ERP. One was still running on VB6 codes and other was running on dot-net platform. We merged them into one dot net platform. This has opened way for use of latest technologies. With this change, we brought in major modifications and entirely new ERP came into existence. With this we also addressed shortcomings and suggestions received in the past.

2016, Most of reports were static in nature. We made these reports dynamic so that user can analyze the data in different ways. Number of reports were merged and simplified with increased functionality. 

How Smaac-Tex can Help your Business?

It is unique software which will help the industry in so many ways. Target of this ERP is to improve processing margins.

1.      Rejections/Re-work is vital area for improvement in a process house. Smaac-tex helps in reducing time taken for Re-works. Multiple analysis on Re-work/Rejections helps in focus and reduction.

2.      We can fix minimum rates of processing for different processes or shade categories and implement the same through ERP. We can link these minimum rates with cost of Recipe + overheads.  Also, we can define process loss for different processes and categories. These recipe costs are saved along with WCO and later compared in daily production report in case there are any differences

3.      Whenever rates are below prescribed limit mail is sent to Directors for their approval. We can choose shade from computer color pallet for visual understanding of shade.

4.      Documents can be approved from the mail itself without visiting ERP.

5.      Costing sheet in the ERP is a class document covers all type of expenses leaving no scope for any error. Costing parameters can be fixed by management so that costing is standardized for the organization. Based on costing offers are sent from ERP to clients. Once order is received offer can be linked with Knitting PO (Ktp) and Processing Work order (WCO) which helps in reducing data entry.

6.      While creating Knitting PO (Ktp) help is available for different fabrics showing parameters obtained in the past. This help reduces dependency on the skill of an individual.  Work order can be issued to multiple knitters against Ktp.

7.      Fabrics could be received for processing against multiple heads (Sales, Knit plus dyeing, job-work, Re-processing, etc.). For internal transfer from knitting entry only need to be approved by grey store.

8.      Reference of WCO can be given while receiving the fabrics or it can be given later at time of lot making.

9.      Dyeing lot are made in the ERP.  Fabric is selected from WCO and balance fabrics available for lot making is displayed for selection. Virtual lots taken in dyeing planning takes preference while making lots. Actual weight loss in the previous lots is considered while calculating the weight for lot. Once lot is created it becomes part of lot register and its location is tracked till it is dispatched. Greige stock is considered before lot making and WIP thereafter.

10.   Lot once created can be planned for lot opening/reversing as limited space at times need working just in time. Dye slip can be created once lot are made. One dye-slip can consist of more than one lot for processing. Lab recipe and dyeing program (used on dyeing m/c) are selected in the dye-slip which reduces data entry.

11.   On real time basis dye-slip need to be loaded on the machine (this resembles fabric loading on dyeing m/c). Previous dye-slip need to be unloaded before a fresh dye-slip can be loaded. This gives real time information of production. After unloading lot can be approved for finishing or it can be rejected. On rejection lot can be taken for Re-Process.

12.   Based on different processes defined in WCO for each fabric lots are categorized for processing. Production is recorded against different processes and machine efficiencies are calculated along with process parameters. Lots are reported where processes are done without WCO.

13.   On QC approval packing list is created for the lot where weighing scale is directly linked with ERP and roll sticker is printed against each roll. At this stage fabric can be rejected as scrap or part/all can be sent for internal reprocess. All the packing slips are available for dispatch advise or challan for dispatch. Billing amount  along with taxes is calculated as per WCO.