Why Weaving Data Still Lives on Boards and Registers
Most weaving sheds capture loom wise data on hand‑written cards that are keyed into Excel much later. Decisions are taken using yesterday's data. Bolto ERP replaces scattered registers with a central, real‑time production view. The traditional approach to data collection in weaving units is fundamentally flawed – supervisors walk through the shed, note down production numbers on paper cards, and these cards are collected at the end of the shift. Someone in the office then keys this data into Excel, often the next day or even later. By the time management sees the numbers, they're already outdated and of limited use for decision-making. The problems with this approach are numerous – handwriting can be illegible, cards can be lost, data entry introduces errors, and there's no way to verify accuracy. More critically, the data is disconnected – production numbers don't link to quality issues, machine breakdowns, or material consumption. Management can't see the full picture because information is scattered across multiple registers, Excel files, and people's memories. When a buyer asks about delivery status, someone has to manually check multiple sources and compile the information, which takes time and is prone to errors. Quality issues are tracked separately from production, so it's difficult to correlate problems with specific looms, styles, or operators. Machine maintenance records are in yet another register, making it impossible to see if breakdowns are affecting production. This fragmented approach means that decisions are made with incomplete information, leading to suboptimal outcomes. For accurate production costing, you need integrated data. Bolto ERP changes this by providing a single platform where all data is captured in real-time, linked together, and immediately available for analysis and decision-making.
Beam and Loom Planning in One Screen
With Bolto ERP you plan beams, assign them to looms and track the progress of each style from warping to grey inspection. Supervisors know exactly which looms are free, which are running, and what is getting delayed. The planning module in Bolto ERP provides a comprehensive view of the entire weaving operation from start to finish. When an order comes in, the system helps you plan the complete workflow – from warping beam preparation to sizing, loom assignment, and final grey inspection. The beam planning screen shows all beams in various stages – which ones are ready, which are in warping, which are being sized, and which are ready for loom loading. This visibility prevents bottlenecks and ensures smooth material flow. Loom planning is equally sophisticated – you can see the status of every loom at a glance. Which looms are running which styles, which are idle, which are under maintenance, and which have completed their assignments. The system considers loom capacity, style requirements, and delivery schedules to suggest optimal assignments. When you assign a beam to a loom, the system automatically tracks progress – how many meters have been produced, how many picks have been completed, and how much time remains. If a loom stops due to a breakage or mechanical issue, the downtime is immediately recorded, and the system can suggest alternative assignments to minimize delays. Supervisors can see real-time updates on their mobile devices, so they don't need to be physically present in the shed to know what's happening. The system also provides alerts for potential issues – if a style is running behind schedule, if a loom has been idle for too long, or if quality issues are detected, supervisors are notified immediately. This proactive approach to planning and monitoring transforms weaving operations from reactive to proactive, enabling better resource utilization and on-time delivery.
Capturing the Right KPIs – Not Just Meters
Meters alone don't tell you the real story. Bolto ERP records picks, stops, mechanical / electrical down‑time and quality rejections so you can see which looms, styles or counts are truly efficient. Traditional production tracking focuses on output metrics like meters produced, but this gives an incomplete picture of weaving efficiency. Two looms might produce the same number of meters, but one could be running smoothly with minimal stops while the other experiences frequent breakages and quality issues. The true cost and efficiency of production depends on many factors beyond just output – machine utilization, downtime, quality, and resource consumption all matter. Bolto ERP captures comprehensive KPIs that provide a complete picture of performance. Picks per minute is a critical metric that shows actual loom speed and efficiency. The system tracks every stop – whether it's due to warp breakage, weft breakage, mechanical issues, or electrical problems. This granular data helps identify patterns – are certain looms more prone to breakages? Are specific styles causing more problems? Is there a correlation between yarn quality and breakage rates? Downtime tracking is equally important – the system records not just when a loom stops, but why it stopped and how long it took to resume. This helps identify maintenance issues, operator training needs, and process improvements. Quality metrics are integrated with production data, so you can see not just how much was produced, but how much was acceptable. Rejection rates by loom, style, and operator provide insights into where improvements are needed. The system also tracks resource consumption – yarn usage, sizing material, and utilities are all linked to production, enabling accurate costing. This comprehensive KPI framework enables data-driven decision-making, helping you identify best practices, address problems proactively, and continuously improve efficiency.
Costing That Matches Reality
Because yarn, sizing, processing and overheads are attached to styles and beams, the system can show you the true cost per meter or per pick. This helps you quote confidently and stop loss‑making orders early. Accurate costing in weaving units is challenging because costs vary significantly based on multiple factors – yarn quality and price, style complexity, loom efficiency, breakage rates, and overhead allocation. Traditional costing methods use standard rates and assumptions, which rarely reflect reality. A style that looks profitable on paper might actually be losing money due to high breakage rates or quality issues. Conversely, a style that seems expensive might be highly efficient and actually more profitable. Bolto ERP solves this by building costs from actual production data. Yarn consumption is tracked beam-wise, so you know exactly how much yarn was used for each style. Sizing material consumption is similarly tracked, accounting for actual pick-up rates. Processing costs are allocated based on actual machine running time, not estimated hours. Overheads are distributed based on real utilization, ensuring fair allocation. The system calculates costs at multiple levels – per meter, per pick, per beam, and per style. This granular costing enables precise pricing decisions. When a buyer asks for a quote, you can confidently price based on actual costs rather than guesswork. The system also provides cost comparisons – you can see how costs vary across different looms, operators, or time periods, helping identify opportunities for improvement. Perhaps more importantly, the system enables proactive cost management. If a style starts showing higher-than-expected costs due to breakages or quality issues, you're alerted immediately. This allows you to take corrective action before losses mount, or even decide to stop production if the style is fundamentally unprofitable. This real-time cost visibility transforms costing from a backward-looking exercise to a forward-looking management tool.
