Gelal Corap

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

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

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

ERP for Textile - 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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