Lot-wise textile ERP and job-work reconciliation for Shreya Print

Highsense Infotech built a textile ERP for Shreya Print in Surat covering lot-wise tracking, job-work challan reconciliation with outside processors, shade and grade control, per-metre costing and a buyer CRM.

The problem

Surat textile processing runs on job work, and job work is exactly what standard ERP handles worst. Grey fabric goes out to a dyeing or printing house on a challan, comes back short, and has to be reconciled against what was issued. Shreya Print was tracking issued-versus-received in registers, so pending challans were only visible to whoever kept the book, and shortage per processor was a suspicion rather than a number.

Lot identity was the deeper problem. When a shade complaint came back, tracing which lot it belonged to and which process house had handled it meant reconstructing the journey from memory. Costing had the same gap: yarn, job work, wastage and rework were blended into an average cost, so nobody could say what a particular quality actually cost per metre.

What Highsense Infotech built

We made the lot the unit of record. Every metre carries its lot from yarn or grey receipt through to dispatch, so a shade complaint traces directly back to the batch and the process house that handled it. Yarn, grey fabric and finished goods are held as separate stocks with their own movements and alerts, rather than one pooled figure.

Job work is issued, received and reconciled as a first-class workflow. Challans are raised against a processor, and pending challans are visible at all times instead of living in a register. Metres issued versus metres received are recorded per processor, so shortage becomes a percentage you can compare across process houses rather than an argument at month end.

Process routing models the real stages - dyeing, printing, washing and finishing - so at any moment you can see which lot is at which stage. Shade approval, grade assignment and rejection are recorded against the lot before it can move forward. Costing closes per lot, giving a true cost per metre instead of a blended average. On the sales side, a buyer CRM holds enquiries, follow-ups and meetings, and sales orders reserve specific lots so dispatch documents carry lot, shade and metres without re-typing.

Inside the system

What changed

• ✓
  A shade complaint traces to the exact lot and the process house that handled it, instead of being reconstructed from memory.
• ✓
  Pending challans are visible to anyone, not only to whoever keeps the register.
• ✓
  Shortage is a percentage per processor that can be compared, rather than a month-end dispute.
• ✓
  Cost per metre is real per lot instead of a blended average across qualities.
• ✓
  Dispatch documents carry lot, shade and metres without anyone re-typing them.

Technology