STYLEman ERP is a .net-based, multilingual enterprise manufacturing application designed specifically for clothing and footwear manufacturers.
STYLEman has been designed from the outset to cater for garment and footwear production. The product setup is inherently colour and size dependent and allows the use of fittings (for example, leg lengths, bra cups or shoe widths) if required. It’s a multi-level solution that allows for data to be entered at any level in the matrix, so costs, prices, or BOM items, for example, can be entered at any level of style, colour, fitting or size as appropriate.
Bill of Materials
The true multidimensional structure of STYLEman makes itself very evident in the Bill of Materials.
In a generic production system (ie, not designed for garments or footwear) each SKU (colour/size) will need its own BOM so that for a style with 4 colours and 6 sizes, each material item (even if it’s the same for all colours and sizes) must be entered 24 times.
STYLEman allows materials (or sub-assemblies) to be attached to the style at the most appropriate level and has a clever maintenance program designed for rapid input of the BOM. A material that is the same regardless of colour or size will only need entering once and is automatically inherited by all variants within the style.
The Bill of Materials also allows individual materials to be posted to different steps in the style costing, so if you want to break materials down to a more detailed level in the costing, trim items can be posted to the “trimming line” in the costing and main materials can be posted to the “main materials” line, for example.
Powerful facilities exist to mass-duplicate, duplicate and change, substitute materials immediately or in the future, and track full BOM change history.
Sales Order Processing
Sales contracts from your customers can be entered into STYLEman via EDI, B2B web order entry or manually through the efficiently simple Order Entry program.
An individual or group of sales orders can be used to calculate material requirements immediately and create production orders or third party CMT orders at the push of a button.
Customer specific critical path formats allow you to follow up on the events that are essential for your customers. STYLEman has in built workflow to notify merchandisers, production planners, stores and shop floor personnel of imminent and overdue critical path events. This ensures everyone in your organisation is aware of the status and progression of every production order and the impact this may have on customer delivery.
Materials Purchasing and Inventory
Raw materials (and sub-assemblies) can be purchased manually by the operator or generated automatically from the MRP module above.
A material purchase order can contain multiple raw material items with multiple delivery dates if required. The critical path attached to every material purchase order ensures the relevant personnel are notified when an event becomes imminent.
Material purchase orders can be raised as unconfirmed, requiring authorised personnel to approve and confirm before sending to the supplier.
Multiple currency costing with budget and actual exchange rates allow you to accurately compare your budget material costs to the actual receipt costs.
Stock receipts and GRN generation can be performed using Wi-Fi scanners in multiple warehouses and locations. STYLEman supports full Case/Roll control and the details of each unique Case/Roll can be recorded at the time of receipt, allowing unique bar-coded labels to be generated.
Full stock movement auditing is provided against all stock movements (receipts, adjustments, transfers, stock count, issues, consumption, returns).
If your company has inspection machine facilities for fabric rolls, the data collated by the inspection can automatically be used as a GRN into STYLEman.
Cutting Room Planning
Our unique cutting planning solution is used for optimized scheduling and monitoring of garment cutting activities in apparel manufacturing. It provides on-time delivery of cut fabric to meet production demands, planning and monitoring of the entire cutting cycle at the click of a button and efficiency based employee rewards.
We provide a comprehensive set of tools to assist in the planning process which include embedded fabric cutting expertise, convenient import of customer orders from any external system, import of relevant bills of material from an external system, simple creation of cutting dockets from one or multiple factories, assignment of markers to dockets from marker library and generation of optimized cutting schedule in sync with sewing plan.
Operations can be monitored at each stage of the cutting process using barcode scanners. Reports are provided to monitor production throughput and efficiencies for teams and individuals.
- Dockets can be created to cut production order fabric requirements
- A single production order can be distributed among many dockets, or many production orders can be assigned to one docket
- Fabric, style, size details and the number of layers of fabric for cutting can be specified
- The cutting machine for a docket can be selected
- Fabric specific cutting requirements i.e. relaxation, post-laying and post-cutting durations can be specified
Production Receipt and Despatch
As product comes off the production line it can be scanned into cartons and a carton label will be generated.
As a carton is received into the stores it can be assigned onto a customer shipment. A shipment can be one or many orders grouped together ready for despatch.
Despatching is a simple process where the shipment number is selected and the weight, cube and bill of lading details are entered. Full traceability is maintained from the shipment header to the sales orders, carton contents, packing lists, despatch notes and invoices. Invoices can be raised and emailed automatically.
STYLEman uses flexible costing formats to allow you to build up the standard costs of a style using the components you use in your business. The component parts of a style costing can be built up automatically from the Bill of Materials and the Bill of Labour (Routing), with additional items, for example overheads or margins, either calculated on a percentage basis or entered manually.
The initial product costing is used as a standard base and all production order actual values are recorded and compared to the base costing for real margin analysis.
Bill of Labour (Routing)
The multidimensional structure of STYLEman is also evident in the Bill of Labour.
In a generic production system, not designed for garments or footwear, each SKU (size) will need its own BOL, so that for a style having 4 colours and 6 sizes, each operation (even if it’s the same for all colours and sizes) must be entered 24 times.
STYLEman allows operations to be attached to the style at the most appropriate level and its clever maintenance program is designed for rapid input of the BOL. An operation that is the same regardless of colour or size will only need entering once and is automatically inherited by all variants within the style.
If you currently use GSD to plan the operations of a style, this data can be imported into STYLEman automatically.
Materials Requirements Planning
Raw material inventory and purchases can be planned in a number of ways in STYLEman.
If sales contracts are not yet available, you can still plan your material requirements. Sales forecasts can be entered by style, colour and size or by selling ratios across colours and sizes. Forecast quantities by period for some styles can be combined with actual sales quantities for other styles and the combined values are then multiplied through the Bill of Materials to calculate the requirement.
Weekly requirements are then compared to current inventory and existing inbound purchase orders to calculate a suggestion to buy. Scrap allowances, buffer stock thresholds and stock in QC can be included in the calculations if required.
The suggested quantities for raw materials and multi-level subassemblies can be automatically purchased from the MRP.
From Contract/Sales Orders
If you already have sales contracts and prefer to purchase materials specifically to one or a group of contracts, STYLEman will allow you the flexibility to achieve this. Simply enter one or many sales order numbers and STYLEman will calculate what’s needed and allow you to modify the suggested suppliers, delivery dates and quantities.
The suggested quantities for raw materials and multi-level subassemblies can be automatically purchased from the trial kitting.
From Production/CMT Orders
If you prefer to group sales orders up into production and/or CMT orders before planning the materials, STYLEman will also allow this.
Simply enter the production or CMT order numbers and STYLEman will calculate what’s needed and allow you to modify the suggested suppliers, delivery dates and quantities.
The suggested quantities for raw materials and multi-level subassemblies can be automatically purchased from here and the resulting material purchase orders are linked and tracked against the parent production or CMT order.
STYLEman can integrate into several different graphical planning tools, providing quick, simple and visual means of scheduling and loading orders directly against factories, production lines, machine types or any other key manufacturing resource. Planning Boards can be loaded directly from STYLEman with styles, orders and material production orders, which may then be visualised on the board, changing colour dynamically as they are rescheduled to indicate early, on-time or late completion.
An intuitive, simple graphical interface allows all problems to be seen on one screen and re-planning is as simple as moving orders with the mouse.
Material Allocation & Issues
Facilities exist to allocate (reserve) material stocks to production/CMT orders as they become available. Allocation can be performed at the production order level for all materials or at the material level for all production orders.
Materials are issued to the production floor as required. Issuing is a Wi-Fi scanner-based activity where rolls or boxes are scanned and automatically moved into WIP. An ad-hoc issuing program allows the stores to send additional items required by production to WIP.
Issuing materials to a third party CMT order allows all the materials sent to the sub-contractor to be tracked for accurate consumption.
Work In Progress
The STYLEman WIP module allows production to be tracked using line or modular production methods.
Bar-coded stickers are produced with each operation and SMV to the bundle quantity of your choice. Scanning of both the operator and individual operations stickers allows detailed analysis of the operators’ performance and efficiency. This analysis rolls up to the module/line/factory levels.
Inline quality monitoring and recording allows accurate analysis of reworks and rejected items.
Scanning of the bundles provides real-time progression of the quantities through the production order WIP stages providing accurate information to the production planning and merchandising teams.