Case study · Socks manufacturing
A socks manufacturer brought knitting, finishing, outsourcing and costing onto one system — and was fully live on Wizmen in five months.
Overview
MSL makes socks, a business where margins are counted in pairs. Each order moves through knitting, dyeing, pressing and packing, often with some steps sent out to subcontractors, and the cost of every pair is shaped at each one. MSL asked Wizmen for a system that followed the order through the whole floor and put an exact cost on it. The implementation was completed in five months.
01The challenge
Small differences in yarn, machine time or outsourced work add up quickly over thousands of pairs. MSL needed to see them on every order, not at the end of the month.
Each order passes through knitting, dyeing, pressing and packing, and had to be tracked at every stage.
Yarn and materials had to be issued against the bill of materials, so consumption could be checked against plan.
Work sent to subcontractors needed to be followed out and back, with its cost added to the order.
The true cost per pair had to be known in time to price the next order.
02Our approach
We built the system around the job order, so every stage records what it received, what it produced and what it cost — and hands a complete record to the next.
Sales orders become job orders with their own bill of materials, so every order starts with a plan for yarn, materials and output.
Yarn and materials are issued against the BOM, so consumption is controlled and variances show up immediately.
Knitting, dyeing, pressing and packing are tracked as they happen, with machine efficiency and material consumption reported daily.
Subcontracted work is followed out and back, and its cost rolls into the order alongside materials and conversion to give a cost per pair.
03The solution
The deployment is built on Wizmen’s Socks Production & Costing System, running on the Wizmen Oracle ERP backbone.
Built on Socks Production & Costing System
Explore the platform04The outcome
MSL went live on Wizmen in five months, and now runs its floor and its accounts from the same records.
Planning, production, outsourcing, costing and finance were all implemented and running within five months.
Materials, conversion and outsourced work roll into the cost of each order, so pricing is set on real figures.
Knitting, dyeing, pressing and packing report as work is done, with machine efficiency and consumption visible daily.
Work sent to subcontractors is tracked out and back, so nothing is lost between the floor and the accounts.
5
Months to go live
In socks, the margin is made a pair at a time. We built a system that counts every one — and had it live in five months.
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