Yarn fabrication production process in SAP ERP solution


This document include :Production planning process,Production planning process,Production scheduling process,Spinning fabrication process ,Spinning fabrication routing,Machine maintenance process

1.Production planning process

Assess factory capabilities

Assess capabilities of machine and labor. The capabilities depend on which finished products / semi – products are processed

Consolidate last year’s production

The production planning for the next year is carried out in September or October of the current year. Thus, the revision for the plan at the end of the year is essential

Evaluate demand

The Spinning Sales Department is responsible for forecasting which products have high demand to prioritize for next year production

Production planning process SAP ERP for Yarn Industy

Plan master production

According to the production capabilities and demand forecasting, Director of Spinning Division and Factory Directors consolidate plan for next year’s production yield. Production capabilities play critical part in planning master production. Production yield must be approved by General Director and is the basis for evaluating level of target achieved by factory.

There are two types of production yield: pure production yield and converted production yield. Pure production yield is the exact volume produced. Converted production yield is the volume converted based on the yarn count. As the high yarn count is hard to produce but weight less than the low yarn count, the conversion step is essential to reflect the actual load of production.

Check inventory status

Material used for producing is quite few/simple, including cotton and polyester filament, visco filament. Inventory status of certain material is checked before purchasing order is processed.

Plan material requirements

Material requirement planning is made in advance for in-time preparing for production. Generally, purchasing lead time for raw cotton is 3 months, for polyester filament is 2-3 weeks.


  • Production planning must be compatible with factory’s capabilities, make the best use of manufacturing capacity and meet the production target.
  • Production planning is appropriate to market trend and demand
  • Material requirement planning can be consolidated immediately once the production plan is confirmed.

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