Enterprise solution
Cost, Scrap and Profitability System
A model that calculates cost, scrap and profitability per order, turned into applications running inside the ERP and into management reports.
Dashboard
Dyehouse JET Production Tracking Screen
A wall-screen application that shows the live status of every JET dyeing machine, the upcoming job queue and the daily output report straight from ERP data.
Illustrative image
Challenge
The supervisor, planner and shift lead had to search the ERP one by one to answer “what is running in which machine?”. When an operator started a job on a different machine than planned, screens showed the wrong picture; queue changes reached the floor by word of mouth; and missing lot scans or batch mix-ups were usually noticed only after the job had finished.
Solution
We built a tracking application that connects to the ERP database with read-only access, computes the business rules on the server and serves a ready-made view to the factory LCD. Each machine is a column: the running job, the queue and the latest outputs in one place. The actual machine an operator started on is detected, the queue mirrors the ERP plan exactly, and scanning errors show up as alerts on the card while the job is still running. A second module, the daily report, lists outputs by shift day and exports to Excel in one click.
Outcome
- All machines on one screen — status is seen at a glance, not asked by phone
- Jobs appear on the machine they actually run on, not the planned one
- Batch mismatches, missing lot scans and jobs awaiting recipes raise instant alerts
- Data query time dropped from about 1 min 45 s to about 4 s
- Nothing is written to the ERP; existing use continues unchanged
Solution process
- 01
Listening to the floor
We mapped how information flows today and when each kind of error is noticed, together with supervisors, planners and operators.
- 02
Validating the data
We studied the ERP production plan, scan and completion records and defined the rules the screen is computed from.
- 03
Lightweight architecture
Three light queries instead of one heavy query, with business rules on the server; the screen only reads the ready result.
- 04
Readable from a distance
Large type, a dark industrial theme, hands-free auto-scroll and a 5-minute refresh.
- 05
Tested on real cases
Plan-vs-machine differences, false alarms and incomplete queues seen on the floor became permanent test scenarios.
What’s on the screen?
Each machine card has three sections:
- Running — the job in the machine: order number, colour, weight and capacity fill, process type, customer, full fabric name, batch, opening/heat-set status, start time and elapsed time. No line is truncated.
- Up next — the ERP queue: the planner’s ERP order is mirrored exactly. The first two jobs are always visible, the rest are a scroll away; the header shows how many jobs are waiting.
- Latest outputs — machine history: the last job out of that machine with date and time; one tap opens the last five. History is back immediately even after a restart.
Errors surface before the fabric goes in
- Batch mismatch: if two different batches are started on the same machine, the card gets a red frame and both numbers are shown.
- Missing lot scan: if a batch has four lots and three were scanned, a “3/4 lots scanned — 1 missing” alert appears.
- Awaiting recipe: jobs whose dye batch has not been created yet are flagged in the queue.
Daily machine output report
The report follows the 08:00 → 08:00 next day shift day rather than the calendar day, so night shifts land on the right date. Time, machine, batch, work order, order, customer, colour, fabric, process, lot and weight are listed line by line. The CSV export handles Turkish characters and decimal separators and opens directly in Excel.
Without touching the existing system
The application connects to the ERP read-only; nothing is written, updated or deleted. If the connection or a query fails, the screen doesn’t go blank: the last good view stays up and a warning appears in the status bar.
How it adapts to your company
The same structure works beyond dyeing: knitting, weaving, garment lines, drying and heat-setting, packing or warehousing. Machine/station lists, card fields, alert rules, shift hours and report columns are defined around your own ERP and workflow, and the screens follow your brand identity. Shift summaries, automatic e-mail reports and rollout to other departments can be added as next steps.
All values in the images are demo data and contain no real production or customer information.
Tailored to your company
This isn’t an off-the-shelf package; we can rebuild the same approach around your data sources, business rules and teams.
- With your dataERP, database, Excel or API — without touching your existing system, using a read-only connection where needed.
- With your rulesAlerts, approval steps, calculations and reports are defined around your processes.
- With your screensAn interface in your brand identity — wall screen, desktop, mobile or admin panel.
- Built to growStart with a single module and extend it with new departments, users and integrations.
Technologies used
- .NET 8
- ASP.NET Core
- Dapper
- SQL Server
- Vanilla JS
- LCD / kiosk
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