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Manufacturing

Full-stack ERP rollout for a vertically-integrated textile mill

Yarn-to-finished-fabric on one ERP — WIP inventory down 25%; per-batch margin visibility same-day.

11 monthsClient: Textile mill · vertically integrated
−25%
WIP inventory
−18%
Cycle time
weeks → 4 hours
Bottleneck detection
Same-day
Per-batch margin visibility
The transformation

Before vs After

BeforeWhere they started
·Sales
·Inventory
·HR
·Payroll
·Accounts
·Reports
  • Yarn / weaving / dyeing / finishing as islands.
  • WIP inventory ballooning.
  • Bottlenecks discovered too late.
  • Per-batch costing weeks after sale.
AfterWhere Sphyx took them
✓Sales
✓Inventory
✓HR
✓Payroll
✓Accounts
✓Reports
🧵
−25%
  • Single batch ID across all stages.
  • WIP dashboard with bottleneck alerts.
  • Shopfloor signoffs on tablets.
  • Per-batch margin same-day.

The challenge

A vertically-integrated textile mill ran yarn, weaving, dyeing, and finishing as separate islands. WIP inventory ballooned because nobody saw the whole cycle.

Our approach

A sequential playbook — each step builds on the one before it.

1

Single batch ID flows yarn → weaving → dyeing → finishing.

2

Per-stage WIP dashboard with bottleneck alerts.

3

Shopfloor tablets for stage-completion signoffs.

4

Costing rolled up per batch in real time.

Outcomes

WIP inventory
−25%
Cycle time
−18%
Bottleneck detection
weeks → 4 hours
Per-batch margin visibility
Same-day