Gelal Corap SA

Labor cost reduction, management reporting acceleration, and revenue growth for the textile manufacturing company.
Challenges

Challenges

Lack of flexibility, production planning, and control capabilities

Gelal Corap Sanayi A.S. is a leading socks manufacturer in Turkey with two production facilities in Çankırı and Istanbul. The company also has more than 1500 employees.

Historically, the company did not have an all-in-one solution for business management and production planning — this lead to a range of inefficiencies, a lack of flexibility, poor planning, and control. 

The main challenges for Gelal were:

Multiple business automation solutions, including two ERP systems working simultaneously
The need to integrate an ERP with industrial robots used at the production facilities
A lack of capabilities to optimize employee performance and knitting machines effectiveness
Planning for the equipment load
Warehouse management

Company's owners set a number of strategic goals such as: opening 300 retail stores across the country, entering new markets, complete reorganization of the company, and profitability increase.

During the implementation, the following business processes were automated:

Sales

Accounting

E-Invoice

E-Ledger

E-Waybill

Production

Quality control

Industry 4.0 integration

Facility maintenance management

Increasing the market share and profitability in a very short time

CUSTOMER SUCCESS

“This is a unique project because we needed a custom solution that will be tailored to our production needs, allow us to achieve better results, and stay compliant with the local Turkish legislation. 1C:Enterprise is a perfect fit for us due to its flexibility, adaptability, and scalability.”

— Mr.Nazmi Doğan, 

Production planning manager, Gelal Çankırı

Results

Results

Real-time production control, better planning, and labor cost reduction

The implementation process was divided into several stages. First, DND, the 1Ci partner in Turkey, conducted a thorough analysis of the Gelal business processes and requirements. Then, 1C:Enterprise ERP integration with industrial robots was designed. Afterward, the employees and the production machines' performance evaluation module was developed. A planning system for the knitting machines was created as well. After these preparations, warehouse management, finance, and accounting business processes were automated. 

A total of 125 seats were automated, including 65 users in the Çankırı factory and 60 workings in the Istanbul facility. The whole project took approximately three years: one year for the Çankırı factory automation and two years for Istanbul.

Overall, the Gelal company was able to achieve the following results:

Due to the more efficient business processes, the production potential has increased. As a result, global sports goods distribution brands, the biggest Gelal socks purchases, increased the volume of their orders by 20%
Labor cost was reduced by 10% due to the integration of the 1C:Enterprise with the industrial robots
The implementation of the industrial machines management module allowed achieving 7-8% productivity improvement
Management reporting became 20% faster

1C:Enterprise implementation benefits:

Increasing the market share and profitability in a very short time
Labor cost was reduced by 10%
7-8% productivity improvement
20% faster management reporting

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