My SAP ERP

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My SAP ERP
Textile Industries
Deepak Sharma SAP Consultant M 09971044884
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Growing concerns for CXOs
How do I address
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Something Familiar.
Manufacturing
Sales
Finance
H R
Inventory
Purchasing
1,000 island solution
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Results of Isolation / Interfaced Solutions

• Focus on Functions
• Interfaced Systems (lots of Reconciliations)
• Inconsistent Redundant Data
• Consolidation Management Control Difficult
• Difficult to monitor Process Productivity
• Reaction to Change Slow
• Applications Developed over time in response to
  differing corporate stimuli.

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Benefits of an Integrated SAP System

• Focus on Process not on functions.
• System Dependency not People Dependency.
• Integrated System (..no time lost in
  reconciliation).
• No Duplication of Efforts.
• Everyone in organization is on same piece of
  Information.
• Real time information available to management
  for quick pro-active decision making.
• Pro-active not re-active.

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Characteristics of SMB organizations

• Small Business doesnt mean simple business
• Prefer Partners who understand their Industry
• Adaptable to standard best practices
• Cannot afford large IT teams

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Primary Pain Points of SMB Companies

• Affordabilibty
• Time to implement
• Resources required to implement the project
• Project Risk

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SAPs approach to address the Small Midsize
market

• With the right combination of industry expertise
  and partners SAP offers small and mid-sized
  businesses the right solution at an affordable
  price implemented in a short amount of time with
  ZERO RISK

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mySAPTM All in One Solutions
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Presenting Tailor-made Solutions for SMBs

• Pre-configured with Best practices
• Designed specific to SMB sector
• Single window operations

• Reduced Ownership Cost
• Industry Specific Solution
• Faster Implementation

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mySAP All-in-One Tailor Made Solution for SMBs

• A cost-effective, vertical out-of-the-box
  solution based on mySAP Business Suite
• Jointly developed and packaged by SAP and SAP
  partners
• Qualified by SAP
• Offered and deployed by SAP partners

• Providing customers with a
• Industry Best Practices
• Complete, scalable tier one industry-relevant
  solution at a low price
• A rapid return on investment
• Strong level of support and service
• Support of commerce between corporation of all
  sizes

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MySAP All-in-One Solutions
mySAP All-in-One solutions combine mySAP
Solution, SAP Best Practices and Partner services
into a single, affordable solution that enables a
fast time to benefit.



mySAP Solutions
SAP Best Practices
Partner Services
mySAP All-in-One
Become a Best Run Business
Industry Expertise, Local Services and Support
The market-leading SAP family of industry
solutions running at over 87,000 installations
Implementation Accelerators Based on 30 Years of
Experience
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mySAP All in one Benefits Summary

• Affordable
• Quick Implementation
• Less pressure on internal resources
• One point responsibility
• Industry specific best business processes
• Zero Risk Implementation

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Market Leadership Industry Solutions,
Manufacturing
Solution
Coverage
mySAP Aerospace Defense 7 of Top 10
Run SAP mySAP Automotive 9 of Top 10
Run SAP mySAP Chemicals 9 of Top 10
Run SAP mySAP Consumer Products
All Top 10 Run SAP mySAP Eng. Construction
8 of Top 10 Run SAP mySAP High Tech
9 of Top 10 Run SAP mySAP Mill Products
7 of Top 10 Run SAP mySAP
Mining 6 of Top 10 Run SAP mySAP Oil
Gas 9 of Top 10 Run SAP mySAP
Pharmaceuticals All Top 10 Run SAP
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Customer Success
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Best Run Businesses Run on SAP
Discrete Manufacturing flagship partnerships
Process Manufacturing flagship partnerships
Services industries flagship partnerships
Consumer Retail flagship partnership
SMB and mid-market partnerships
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Some Perceptions

• SAP Is Just for the
• BIG

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Some SMB Realities ..

• Sumeet Exports
• 20 Crores Turnover
• FI, CO, SD, MM, PP, QM, PS
• 4 Months
• Centex Fabrics
• 30 Crores Turnover
• FI, CO, SD, MM, PP, QM, PS
• 4 Months
• Bansal Metal Works
• 60 Crores Turnover
• FI, CO, SD, MM, PP, QM, PS
• 4 Months

Induslogic India 45 Crores Turnover Implementation
in Process Scope FI, CO, SD, PS, MM, HR,
Payroll Tega Industries 30 Crores Turnover FI,
CO, SD, MM, PP, QM, PS 5 Months Unipatch Rubber
30 Crores Turnover Implementation in Process
Scope FI, CO, SD, MM, PP, QM
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. and more

• Sunshine Cosmetics
• 35 Crores Turnover
• Implemented FI, CO, SD, MM, PP
• 5 months
• Weiler Electronics
• 20 Crores Turnover
• Implemented FI, CO, SD, MM, PP
• 7 months
• Medicorp Technologies
• 30 Crores Turnover
• Implemented FI, CO, SD, MM, PP, PM
• 6 months

• Macmillan India
• 80 Crores Turnover
• Implemented FI, CO, SD, MM, PP
• 5 months
• Balsara Hygiene Products
• 120 Crores
• Implemented FI, CO, SD, MM, PP, PS
• 7 months
• Glenmark Pharmaceuticals
• 200 Crores Turnover
• Implemented
• FI, CO, SD, MM,PP,PM,QM
• 7 months

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Few More.

• Usha International
• 350 Crores Turnover
• Implemented FI CO, SD, MM,
• 9 months
• Bhartia Cutler Hammer
• 85 Crores Turnover
• Implemented FI CO, SD, MM, PP, PM, HR, Payroll
• 8 months
• Amit Spinning
• 60 Crores Turnover
• Implemented FI CO, SD, MM, PP, PM
• 4 months

• Aarthi Industries
• 350 Crores Turnover
• Implemented FI CO, SD, MM, PP
• 6 months
• Messung Systems
• 18 Crore / 54 Crore Turnover
• Implemented FI, CO, SD, MM, PP, PM
• 8 months
• PI Industries
• 200 Crores
• FI CO, SD, MM, PP, PM, PS, QM
• 7 Months

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Some Perceptions

• SAP Is Very Expensive

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Some Realities-Lowest Total Cost of Ownership

• n x installation
• n x release upgrade
• m x interfaces
• n x training
• n x data transfer
• y rollouts

• 1x installation
• 1x release upgrade
• no interfaces
• 1x training
• 1x data transfer
• 1x rollout

Costs
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For Over 30 Years, SAP Has Been Driving ERP and
We Continue to Do So
mySAP ERP E-Business is now seen as an extension
of ERP, not a replacement. SAP is leading the
new industry standard for collaborative business
applications.
ERP Rapid Adoption Companies start to adopt ERP
on a massive scale Dot.com Hype ERP Old
E-Business New Trends seemed to indicate that
ERP was an out-of-fashion model
ERP The Business Software Industry The approach
that SAP established becomes industry standard.
New competitors enter the market.
SAP Invents Real-Time ERP SAP defines and
establishes a new approach to Integrated Standard
Business Software.
70s
80s
90s
00s
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Steps to Strategic ERP

• Enterprise Resource Planning is evolving through
  three stages

Create Strategic Value
Efficiency and Control
TotalCompanyValue
Automation
80s R/2
90s R/3
Today mySAP ERP
Evolution of ERP
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How SAP Sets a Market-Driven Strategy

Statement of Direction

Development/ Test
ProductionAssembly
ProductionRamp-up
MainstreamRoll-out
Widening Audience
SAP, Market Driven Strategy - Our Commitment to
Listen and Inform
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Textile Industry Today

• TEXTILES
• Production of fabric, yarn, thread, carpet,
  teabag string etc.
• Produced largely for use in the apparel industry
• APPAREL
• Converts Textiles into clothing and other
  finished goods
• Sold on the retail market
• RELATIONSHIP
• Represent two distinct but closely related
  industries

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Textile Industry Characteristics

• MULTIPLE PRODUCTION STRATEGIES
• In-house manufacturing
• at one or more work centres
• at one or more manufacturing locations
• External manufacturing
• through Trading
• through Sub Contracting
• COMPLEX PROCESS MIX
• Multiple processes at the same facility
• LOW TO HIGH END TECHNOLOGY
• Similar output from a Home-setup to a
  state-of-the-art facility
• SEASONALITY
• SpringSummerAutumnWinterChristmas

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Textile Industry

• Mainstay of the economy
• The largest employment sector
• 800 Apparel factories
• Total Exports - USD 2.7 Billion
• Exports to USA - USD 1.6 Billion
• 12th largest supplier of Apparel to US
• Approximate figures

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Global Textile Consumption
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Agenda
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Can the industry afford this?
Textile Industry in South Asia
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Textile Industry Drivers
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Textile Industry Trends
MARKET TRENDS
DRIVING TOWARDS ERP
Shorter Fashion Cycles
Faster Sample Approval Control
PS
Greater Variety
Better Inventory Management
MM
Shorter Production Runs
Complex Production Planning
PP
Better Quality
Quality Systems and Procedures
QM
Lower Prices
Higher Productivity
CO
Outsourcing from few
Bigger, more complex enterprises
MM
Transparent Order Tracking
Integrated Web enabled systems
EP
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Textile Industry Future
PAST
FUTURE
Optimized Business
Processes
External Quota
mySAP ERP
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Concerns

• Cost
• Complexity
• Project risks
• Cost overrun
• Wrong Project methodology
• Wrong Partners
• Future-proof solution ?
• Is it needed ?

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Agenda
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Sapindus Solution
mySAP CRM
MM
FI
PP
mySAP SCM
mySAP PLM
SD
CO
QM
PS
PM
AM
HR
PY
EI
mySAP SRM
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Approach to SAPINDUS Development

• Enable quick and simple implementation of mySAP
  ERP / Business Suite
• Develop a solution that
• is Textile-specific
• requires minimal adjustments on site
• adapts to customer requirements
• embraces the value chain from Fiber to Apparel
• Arrive at a fully documented prototype within
  days that can quickly be turned into a productive
  solution

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Sapindus Features
From Day 1
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Sapindus features contd.
From Day 1
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Fiber to Retail Shelves
Target Segment
is the underlying philosophy of Sapindus

• Yarn Manufacturers
• Fabric Manufacturers
• Garment Manufacturers
• Upholstery Manufacturers
• Home fashion manufacturers
• Carpet Rug Manufacturers
• Sub Contractors for above segments

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Typical Processes Supported in SAPINDUS
While an attempt is made to cover all the
processes, some of the processes may differ
depending upon the manufacturing equipment,
underlying technology, manufacturing processes,
materials used in production, materials produced
etc.. It should be noted that India has old
companies who use old manufacturing technology as
well as young/new companies which use
state-of-art technology and processes. However,
it wouldnt have major impact on the
Pre-configured solution during implementation due
to the fact that these could be easily replaced
in our solution where ever required.
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Typical Processes In Textile Manufacturing
Natural fabrics / Manmade Fabrics
Fiber to Yarn Yarn to Fabric Dyeing Printing
Finishing Cut sew Apparel finishing Packing
Loosening cleaning
Carding
Doubling
Combing
Drawing
Roving
Spinning
Winding
Different types of yarn Ply, Cabled , Doubled,
etc..
Weaving (Shedding, Picking Up, Beating Up )
Knitting (lace making, net making, braiding .)
Natural Dyes / Manmade Dyes
Bale, Batik, Beam, Burl, Chain, Cross Dyeing .
And more
Printing
Styles ( Direct, Discharge, Resist)
Types / Methods of Printing ( Block, Roller )
Greige / Gray Goods
Decating, Tentering, Crabbing, Heat-setting,
Softening
Cut and Sew Operations
Designing, Selection of Fabric, Pattern Making,
Grading, Marking and Laying, Cutting, Sewing
Apparel Finishing Packing
Buttoning, Pressing, Final Checking and Packing
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Yarn Manufacturing Process
Inputs / Raw Material Manmade E.g. Polyester
Chips
CPF system
Extruder
Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel finishing Packing
Molten Polymer
Silo Management
Extrusion
Filtration
Dried Chips
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Chips stored in silos as per grades
Molten polymer filtered of foreign particles
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Polyester yarn With number of filaments
Yarn spun on Cylindrical bobbins
Spinning
Take Up
Texturizing Process
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POY / DTY wound on paper tubes
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Spinning Gear pump, Pack Spinneret Assembly
Winding machine
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SAPINDUS offers to address the following
Production Quality parameters

• Extrusion Filtration Parameters
• Zone temperature set points
• Actual zone temperatures
• Dow therm boiler temperature
• CPF inlet pressure
• CPF outlet pressure
• Extruder screw RPM
• Extruder motor outlet current

• Processes Parameters for Chips
• RPM of Rotary Valve, below wet chips hopper
• Crystallizer inlet air temperature
• Dryer inlet air temperature
• Dryer inlet air dew point
• Dryer throughput per hour
• Dryer outlet chips temperature
• Rate of air flow to the dryer system

Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel finishing Packing

• Spinning Parameters
• Melt pump RPM
• Finish pump RPM
• Beam temperature
• Spin finish type and concentration
• Oil pick up
• Pack combination
• Pack pressure
• Quench air temperature

• Important winding parameters
• Denier / filament of yarn.
• Winding speed.
• Merge number.
• Paper tube color and specifications.
• Bobbin weight

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SAPINDUS from SAPINDUS offers to address the
following Production Quality parameters
Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel finishing Packing

• Production performance parameters
• Total production
• 100 production
• Efficiency
• Total waste produced
• Waste
• Yarn breaks
• Breaks / ton of yarn
• Down time
• Analysis of break down and shutdown reasons

• Grading
• 1st Grade
• SS Grade
• PQ Grade
• CLQ Grade
• Joblot etc.

• Defects Checked for downgrading
• BF
• Loops
• Jail
• Over thrown yarn
• Damage
• Oil stain

• Quality Control and Packing
• Actual Denier
• Elongation ()
• Tenacity (gms/denier)
• Draw-force (cN)
• Uster ()
• Yarn I.V.

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SAPINDUS OFFERS

• Pre-mapped as Characteristics in Quality
  Management
• Pre-mapped as Batch Characteristics
• Pre-defined Analysis Reports such as Quality
  Yield analysis based on these parameters

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Sample Material Coding
Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel finishing Packing
Combination of material code is Ex
PCR001BRA101AA
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Weaving Process
Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel finishing Packing
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SAPINDUS OFFERS

• Production Process Control Beam-wise
• Planned Order generation for the weaving
  requirements through MRP run
• Automatic allocation of production/customer
  order to one or more machine/production order
• Lot tracking Order to Beam
• Quality Check at each stage of Weaving

• Production Process Control Roll-wise
• Planned Order generation for the knitting
  requirements through MRP run
• Automatic allocation of production/customer
  order to one or more machine/production order
• Lot tracking Order to Fabric Roll
• Generation of production orders with roll number

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Dyeing Processes Supported by SAPINDUS
Typical Dyeing Methods Bale Dyeing, Batik Dyeing,
Beam Dyeing, Burl or speck Dyeing, Chain Dyeing,
Cross Dyeing, Jig Dyeing, Piece Dyeing, Random
Dyeing, Solution Dyeing, Yarn Dyeing, Solvent
Dyeing
Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel Finishing Packing

• Dyeing Determinants / Parameters
• Coloration of Fabric
• Absorption

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Printing Processes Supported by SAPINDUS

• Printing Methods
• Block Printing
• Roller Printing
• Duplex Printing
• Stencil Printing
• Screen Printing
• Transfer Printing
• Blotch Printing
• Jet Spray Printing
• Electrostatic Printing
• Photo Printing
• Differential Printing
• Warp Printing
• Airbrush or Spray Printing

• Typical Printing Styles
• Direct Printing
• Discharge Printing
• Resist Printing

Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel Finishing Packing
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Finishing Processes Supported by sapindus

• Finishing Processes
• Singeing / Gassing to give the fabric a smooth
  finish
• Bleaching to give the fabrics white colour
• Mercerizing to make the fibre more lustrous and
  increase the strength
• Shrinking to realize maximum pre-shrinkage in
  finishing
• Stiffening by immersing in a solution of starch
• Weighting increasing the weight of the fabric
  by immersing in metallic salts
• Crepe Crinkled effects
• Shape-Retentive Finishes
• Wrinkle-Resistant finishes
• Soil repellency
• Flame retardants
• and more

Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel Finishing Packing
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Apparel/Garment Processes Supported by SAPINDUS
Fabric Type Color Design / Style Sizes
Quantities Expected Delivery Time
Expected Cost Design Document
Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel Finishing Packing
Inquiry from Customer
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Apparel/Garment Processes Supported by SAPINDUS
Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel Finishing Packing
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SAPINDUS OFFERS

• Coverage of the entire Merchandizing process
• Planned Cost Calculation at the time of
  Quotation
• Material Requirement Planning for the
  garmenting requirements right upto Fabric level
• Production Process Control Bundle wise
• Bundle tracking Order to Bundle
• Sub-Contracting of WIP to vendors
• Payroll Calculation based on Piece Rate
• Bar Code Interface for WIP movement
• Customer Access to online reports on the
  internet as per authorization

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Pre-shipment Documents in Exports
Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel Finishing Packing
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Post-shipment Documents in Exports
Fiber to Yarn Yarn to Fabric Dyeing Printing Fini
shing Cut sew Apparel Finishing Packing
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Seize the Opportunity With SAP
Deepak Sharma Consultant- SAP Practice M
09971044884