VK Garments, Gudiyatham

The challenge

What the floor looked like before

Every morning started with phone calls to supervisors asking what happened on the previous shift. Sewing line counts were written on paper at the end of each shift. By the time the production head knew a line had fallen behind, hours were lost. Buyer packing deadlines were tracked in a WhatsApp group with the merchandising team. Fabric consumption per style was unknown until later, which made it impossible to flag shade-lot mixing before it reached finishing.

What was set up

On FleekERP

FleekERP was configured with style-wise work orders for each active buyer order. Sewing line operators log bundle completions from their Android phones every hour, with no dedicated hardware. The production head's dashboard shows every line's count, target and efficiency without a phone call. Shade-lot fabric allocation is tracked from cutting: each roll is tagged with its shade lot, and the cut plan keeps rolls separated by shade lot within each size group.

Results

What the customer reports

• The production head stopped making status calls. The line dashboard replaced the morning WhatsApp update.
• Buyer packing deadlines met since go-live, with no late shipments in the first four months.
• Shade-lot mixing caught at cutting, before it reaches sewing, so shade-variance rejection at finishing is gone.
• Hourly sewing line data allows same-shift correction when a line falls behind its target.
• First line live in 18 days, with operators trained and logging within two days of training.