Automation and digitalization
time for textiles

The automation infrastructure of the Turkish Textile Industry has the latest technologies in the world to a great extent, but the enterprises cannot use the data collection and evaluation tools provided by this infrastructure sufficiently and cannot integrate the data produced by the systems with ERP systems and ensure the digitalisation of the data.

A lot of information that can be provided to the production machines in the field is processed manually in production software, and at many points, records are collected on forms and recorded in the systems by operators.

Inaccuracies, especially on the basis of field workers and during recording, lead to incorrect data being processed into the systems. In addition, many data produced by automation systems but not recorded are lost without being recorded. (e.g. machine parameters, energy consumption, working times...) However, it is possible to use this data in many areas such as measuring the efficiency of the system, generating accurate costs and tracking anomalies in production.

With the SAP Manufacturing Suite product family, which is an important component of the solutions offered by SAP for Industry 4.0, the entire automation infrastructure is digitalised in an integrated manner with the SAP S/4 HANA ERP solution.

With SAP Leonardo, you can digitise the data in your production systems on the cloud platform with connectors. As an innovation platform, SAP Leonardo offers tools that combine the Internet of Things, big data and blockchain technologies. With the analytical layer it provides, it supports scenarios such as identifying anomalies in production and predictive maintenance with algorithms such as machine learning.

Today, textile manufacturers appear with their wholesale-retailer qualifications as well as their manufacturer identities. While production facilities produce to order and stock, they also meet the needs from different sales channels such as retail, wholesale, B2B, B2C, marketplaces. One of the important problems for textile manufacturers is the allocation of the available stock to orders with different segmentation, location and priorities within this channel structure.

It is observed that the solutions written for the textile sector generally meet the needs of a part of the enterprise, and different solutions should be positioned for other parts. Other examples are that the very good production system software cannot establish the cost structures, and the master data structures with undeveloped integration layers lead to congestion at a certain stage.

You can position SAP S/4 HANA for Fashion and Vertical Business, SAP's sectoral - ERP solution, to manage all textile and retail operations end-to-end. SAP S/4 HANA for Fashion covers the entire function set of SAP S/4 Merchandising for Retail. In addition, it includes production, advanced availability control, seasonality, back order processing, advanced stock segmentation and stock protection processes.

SAP MII, which is under the SAP Manufacturing Suite product family, provides effective production management with functions such as data collection from production, data visualisation, automatic production confirmations with the received data, analysis of downtime in production, OEE calculations, capacity utilisation, productivity calculations, automatic warnings and notifications. SAP MII works integrated with SAP's production management system SAP ME (Manufacturing Execution).

Turkey is one of the important production bases in the world in the field of textile and supplies products to many important brands in the world. Businesses generally use the production method according to customer order while meeting customer needs. Production with small lots, variety of variants and sizes, product diversity and seasonality make the process quite complex. In production facilities where thousands of orders enter every season, master data management and traceability needs come to the fore. There are many important points in the setup of the production process according to the order, from quotation to invoicing. SAP contributes to the process at every stage with the best practices and scenarios.

SAP S/4 HANA, the SAP ERP Solution, supports the production-to-order strategy starting from the quotation stage, customer order, supply of goods based on the order, production, storage, shipment, costing and profitability processes, and ensures the traceability of the customer order at every stage.

We, as Prodea, offer different versions of services to business units in the bidding process with our Bid Costing solution:

• We provide the ability to manage and track cost items such as mould, template and sample production, and to create cost studies and offer files.
• We manage the complex product diversity created by orders by simplifying it with variant configuration features.
• We automate the product tree, business plan creation and pricing processes through options.

SAP aATP solution categorises orders, determines order priorities, ensures availability control and manages the allocation of available stocks to orders. The due dates of the rescheduled orders are revised according to the changing supply and production conditions during the day with the re-scheduling functions. With stock segmentation, it is possible to distribute the available stock to certain logical stocks and to evaluate these stocks under availability control.