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GullySystem
Manufacturing · Software for fabric manufacturers

Follow every warp beam, loom and fabric roll from yarn lot to graded, packed length.

Fabric mills turn yarn into woven or knitted cloth, then send it to be dyed, printed and finished. The software tracks yarn lots, warp beams, loom output, roll numbers, inspection points and outside processing, so each roll has its construction, defects and customer allocation on record.

At a glance

A fabric mill sells length, width and weight. Behind them stand yarn counts, ends per inch, picks per inch, the warp beam on the loom and the roll that comes off it. Buyers ask for a construction, a weight in grams per square metre and a shade. Then they measure what arrives, roll by roll, against the order and against the sample they approved before the first metre was woven.

Much of the money is made or lost between the loom and the packing list. Rolls change hands between weaving, grey inspection, processing houses and finishing. A roll that loses its number cannot be sold with confidence.

How the work runs today

Orders list quality, construction, width, finish and delivery. The planner works out yarn needed for warp and weft, issues cones to the warping section, and builds beams for sizing and drawing-in. Looms or knitting machines are loaded by quality, and operators record metres or kilograms produced per shift. Efficiency follows from stoppages.

Greige rolls reach the inspection table. Defects are counted per length and graded. Fabric goes to a processing house for bleaching, dyeing, printing or finishing, and returns with shrinkage and shade readings. Final inspection, lot matching and rolling follow. Packing lists carry roll numbers, lengths and weights for the order, and the buyer checks them on arrival at the cutting room. Remnants are sold as lots.

Where it breaks

What goes wrong for fabric manufacturers without a proper system.

Yarn lots are lost in the warp

A beam holds ends from several cones and lots. A fault in the cloth, such as a streak, cannot be linked back to the yarn that caused it, so the same cone is used again.

Loom output is counted late

Metres woven per shift are noted on a card and totalled the next day, so efficiency and style change losses are guesses.

Grey and finished lengths disagree

A roll is sent to processing at one length and returns at another, with shrinkage and shade not recorded against it.

Defect points depend on the inspector

Grades are given at the table, and the point count is rarely stored with the roll number.

Remnants and short rolls sit unsold

Short lengths and seconds pile up because stock by quality and length is not visible to sales.

What the software does

What we would build for fabric manufacturers.

Named the way your team already talks about the work. We start with whichever part the audit shows is costing you most.

Yarn lots and warp beams

Issue yarn by lot to warping and sizing, and tie each beam to the looms that use it.

Loom and machine output

Record metres or kilograms per loom and shift. Stoppages for warp breaks, weft breaks and style changes are kept apart, so efficiency can be read by cause as well as by loom.

Roll register and grey inspection

Number each roll and record defect points, length, width and grade at the inspection table.

Outside processing

Send rolls to dyeing, printing or finishing houses and receive them back with length, shrinkage and shade.

Final inspection and packing lists

Grade finished rolls, match lots and print packing lists by roll.

Remnants and stock lots

Hold short lengths and seconds by quality, shade and length, ready to offer to buyers.

Before you talk to a supplier

A requirements checklist for fabric manufacturers.

What to cover, which reports to ask for and what to put to every vendor, ready to print or save as a PDF.

Open the checklist
Ready product

A product already built for fabric manufacturers.

It is adapted to how your business works before it goes live, and anything your trade needs that it lacks is added then.

Fabric Manufacturer Management Software

Yarn lots, warp beams, loom output, roll registers, grey inspection points, outside processing and packing lists for fabric manufacturers.

See the product
Solutions inside

The business modules fabric manufacturers use most.

Each one is also available on its own, or inside a system built for you.

How it works

How the work runs from Bengaluru for your city.

  1. 1

    The audit, by call

    A screen-share and a look at the sheets, accounting reports and WhatsApp groups your team uses. No travel needed.

  2. 2

    A written proposal

    Scope, what we build first and the cost, agreed in writing before anything starts.

  3. 3

    Build in short rounds

    Working screens shared every few weeks. Your team tests them from your own office.

  4. 4

    Go-live, in person when it helps

    For data migration and training we can come to your city. Travel is agreed in advance.

  5. 5

    Support online

    Fixes, changes and hosting handled remotely by the same team that built it.

Common questions

Questions fabric manufacturers ask before they call.

Can each roll carry its own number?

Yes. A roll is numbered at doffing, and its length, grade, processing and customer allocation follow that number.

Does it work for knitted fabric?

Yes. Knitting units record kilograms and fabric weight per roll, while weaving units record metres and width. Both use the same roll record.

How are processing houses handled?

Rolls go out on a sheet by order, and the returned length, shade and shrinkage are entered against each roll.

Can we match lots for a buyer?

Yes. Final inspection groups rolls by shade lot, so a packing list shows rolls from one lot together.

What happens after I share my requirements?

An engineer reads what you send and replies within one business day. We then look at the software, spreadsheets and WhatsApp groups your business runs on today and write down what works, what slows your team down and what is missing. A demo login, a screen-share or a few screenshots are enough. You get a short written summary ordered by priority, with no obligation to hire us afterwards.

How much will the software cost?

We don’t publish a price, because it depends on what the system has to do. That first review settles the scope, and the cost goes into a written proposal before any work starts.

Related

Related industries.

Category

Part of a wider group.

Talk to us

Tell us how your business runs today.

A few lines on your spreadsheets, software and WhatsApp groups is enough. We reply the same working day.

  • No obligation
  • A reply within one business day
  • Your details stay private

Start with your requirements

Seven short steps that tell us what you need. An engineer reads them before getting in touch.

Share your requirements