Garment manufacturing is a relay race across many departments — design, R&D, merchandising, production, purchase and packing — and a dropped baton anywhere costs time and money. We built a custom SAP Business One add-on that digitizes the entire cycle, from first design sample to final dispatch.
The challenge
The manufacturer needed every department working from the same live data — capturing design costs, optimizing materials in R&D, planning production by size and colour, and tracking contractors — all inside SAP, for both make-to-stock and make-to-order models.
What we built
- Designer & R&D costing forms — capture fabric, accessory and labour costs per sample, with images shared automatically for bulk planning and cost optimization
- Merchant & size/colour planning — generate items, bills of material and SAP production orders, broken down by size and colour
- Production planning & job-work — issue and receive materials, assign contractors, and track every batch against a single work order
- Gate entry, combo items and a customized production order screen with shrinkage, vendor and procurement detail
The results
- The full production cycle synchronized across departments, reducing delays
- Lower bulk-production costs through R&D-led material optimization
- Accurate material tracking that minimized wastage and discrepancies
- Faster procurement through direct integration with SAP purchase and production orders