VSTAN Industries Pvt Ltd, Arani

The challenge

What the floor looked like before

Style-wise production planning lived across a stack of spreadsheets, one per style, reconciled by hand before every planning meeting. Allocating orders to the right lines and sizes took hours, and the plan was out of date the moment a style changed. Fabric was issued against a cut plan worked out by hand, so over-consumption only surfaced at month-end stock reconciliation, long after the margin on that order was gone.

What was set up

On FleekERP

FleekERP replaced the spreadsheet stack with style-wise work orders linked to the cut plan. Orders are allocated to lines and sizes from one screen, and the plan updates as production is logged. Fabric is issued against the work order, and actual consumption is tracked per style as the roll is cut, with an over-consumption alert the moment a run drifts past its planned usage.

Results

What the customer reports

• Production planning time cut by about 60 percent, from hours of spreadsheet reconciliation to one screen.
• Fabric over-consumption flagged per style the same day, not at month-end reconciliation.
• Style-wise allocation across lines and sizes managed from one board instead of separate files.
• Planning meetings shortened, since the plan is current before the meeting starts.
• First line live in 18 days, with operators logging from their own Android phones.