Challenge Cutting Bundles Sewing External Fabric Get Started
Background
Developed by Efficient ERP

EG Tracker

End-to-end digital workflow for garment manufacturing

From fabric rolls to final shipment challan — complete traceability, zero paper dependency, floor-level precision at scale.

30+
+ Modules
100%
Web-Based
Multi
BU Support
The Challenge

PAPER KILLS SPEED

Traditional garment cutting rooms run on clipboards, spreadsheets and printed reports — creating delays, errors and zero real-time visibility.

Manual Bundle Cards

Filled by hand — serial numbers wrong, lost on the floor. 12% re-work from serial errors.

Error Rate 12%

Delayed Reporting

Production reports compiled hours after the shift ends — too late to act. 3 hours average delay.

Delay Impact 3 hrs avg

Black-Box Processes

No visibility into external process status — embroidery, print, wash go completely dark.

Visibility 0%
3 hrs
Avg delay in daily report
Manual
Data collected manually
12%
Re-work from serial errors
0%
Real-time floor visibility
✂️ MODULE 01

CUTTING FLOOR CONTROL

From order import to lay plan — automated ratio calculation, table scheduling and real-time cut output recording.

  • Auto-plan with TMR & size ratio overrides (including zero-ratio support)
  • Table Gantt scheduler with drag-and-drop lay assignment
  • Endbit width calculation per roll vs marker width
  • Cut output recording with size-level breakdown
Cut Plan Dashboard
📦 MODULE 02

THE PAPER BRIDGE

Not 100% paperless — and that's by design. Bundle cards are the physical identity of each bundle on the sewing floor. But they're generated digitally with guaranteed serial integrity.

1
Generate cards digitally
QR encoded with bundleid
2
Print & attach
Attach to physical bundle on cutting table
3
Scan QR at sewing line
Record OK/Defect/Rectify/Reject
4
Scan OUT for external process
Challan auto-generated
Bundle Card Generator
🧵 MODULE 03

SEWING OUTPUT LIVE

Every sewing line tracked in real-time. QR scan records production per bundle. Defects mapped to garment silhouette. Efficiency computed per operator-hour.

87%
Efficiency
3.2%
Defect Rate
1000+
Active Lines
Line-01
92%
Line-02
74%
Line-03
61%
Line-04
87%
Garment Silhouette with Defects
Open Seam 12
Skip Stitch 7
Raw Edge 4
Broken Thread 2
🏭 MODULE 04

EXTERNAL PROCESS CONTROL

Full lifecycle tracking for bundles sent to embroidery, print, wash and other external processes — with formal challan printing.

1
Create Challan
Auto-number · Searchable supplier dropdown
2
Scan Bundles Out
QR scan records process + supplier
3
Add Invoice
Invoice No · Amount · Currency
4
Partial Receive
Per-bundle qty · Accumulates correctly
5
QC Check
Pass / Fail · Notes recorded
Delivery Challan
MODULE 05 & 06

FABRIC MANAGEMENT & QUALITY CONTROL

Fabric rolls are not just a list — they carry inspection results that influence which rolls are safe to cut.

🧶 Fabric Rolls

72%
Utilised
1,248m
Available
184
Rolls
  • Transfer rolls between orders · Partial split
  • Supplier + fabrication dropdowns
  • Roll Length vs Used Length (live balance)
  • QR code label for floor scanning

🔍 4-Point Quality

A
Pass
0–28 penalty points
72%
B
Marginal
29–40 penalty points
21%
C
Quarantine
41+ penalty points
7%

Defects are logged per metre position with type, length, warp/weft flag, and points. Rolls receive an auto-computed grade.

📷

Mobile Roll Scan & Trace

Scan any roll QR code to instantly retrieve lot info, available length, quality defects, and which cut plans it has been allocated to. No manual lookup needed on the floor.

scan_roll("RL-2042") → {
roll: { available: "47.3m", grade: "A" },
quality: [ ...defect records ],
plans: [ ...cut plan usage ]
}
Business Impact

Transformative Benefits

Real results that impact your bottom line and operational efficiency.

80%

Faster Planning

Reduce cut planning time by 80% with automated constraint solving and ratio-based lay generation.

0%

Serial Errors

Eliminate bundle misrouting and serial errors with QR-encoded digital bundle cards.

12%

Fabric Waste Reduction

Cut fabric waste by up to 12% with optimized lay planning and endbit remnant tracking.

100%

Real-Time Visibility

Live shop floor dashboards with 3-minute KPI updates and instant defect alerts.

3x

Faster Reporting

Transform 3-hour manual report compilation into instant digital dashboards.

100%

Challan Traceability

End-to-end traceability from order to QC with formal challan printing and partial receive tracking.

0
% Avg Sewing Efficiency
0
% Defect Rate
1000+
Active Lines Tracked
1500000+
Pieces Cut Today

Digital Cutting Room Is Live

Transform your cutting room operations with real-time visibility, zero serial errors, and 100% challan traceability from order to QC.

Real-Time Visibility
Zero Serial Errors
100% Traceability