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

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

Single batch ID flows yarn → weaving → dyeing → finishing.
Per-stage WIP dashboard with bottleneck alerts.
Shopfloor tablets for stage-completion signoffs.
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