How We Replaced Paper, Excel and Tally for a 110-Loom Weaving Mill With One Odoo ERP
Rajeshwari Weavetex ran its weaving mill on paper, Excel and Tally. We replaced all three with one Odoo ERP covering yarn purchase, warping, sizing, weaving and fabric inspection. The mill now tracks wastage at every stage and knows its true cost per metre.
What We Built for Rajeshwari Weavetex
Rajeshwari moved from paper, Excel and Tally to one connected ERP across every stage the mill runs.
110
looms on one system
4
production stages connected end to end
2-way
lot traceability, yarn to roll and back
3->1
paper, Excel and Tally replaced by Odoo
About Rajeshwari Weavetex
Rajeshwari Weavetex LLP is a 110-loom weaving mill in Jalida, Gujarat. It buys ready-made yarn and turns it into grey fabric, the raw woven cloth that comes off the loom before any dyeing or finishing.
The mill doesn't spin its own yarn or finish fabric in-house. So we scoped the ERP to the stages it actually runs:
Yarn Inspection → Warping → Sizing → Weaving → Grey Fabric Inspection → Dispatch
What the Mill Needed
One system to answer "which yarn, which roll, what cost" without anyone digging through paper, Excel or Tally.
One system for purchasing, production, inventory, quality and accounting
Two-way lot traceability, from any roll to its yarn lot and back
Separate wastage tracking at warping and sizing
Roll-wise records with inspection results and defects
True cost per roll and per metre of grey fabric
Loom-level visibility into efficiency and downtime across all 110 looms
Our Approach
How we built it
Odoo Manufacturing works on a simple recipe: issue fixed quantities of material and get a finished product. That suits assembly lines. A weaving mill breaks the recipe in four places.
Kilograms vs. ends and metres: Yarn is issued by weight, but warp beams are planned by number of ends and length. The ERP had to convert between the two.
Different wastage at each stage: Warping loses yarn to breaks and trimming. Sizing loses it to chemicals and process loss. A standard BOM can't track them separately.
Rolls, not bulk output: Most defects start at the loom, so every grey fabric roll needed its own record, not one bulk figure.
Cost spread across stages: Yarn, sizing chemicals per beam, labour and stage-wise wastage all add up. Standard costing misses most of it.
Yarn Procurement and Inspection
Purchase orders, receipts and lot tracking are managed in Odoo, with incoming quality checks performed before yarn is released for production.
Each purchased yarn lot becomes the starting point of the production traceability chain.
Yarn comes in with a lot. That lot doesn't disappear when production begins; it travels through the entire process.
Warping
Warping required more than a standard material consumption calculation.
Custom BOM logic calculates yarn requirements ends-wise against the target warping length, while accounting for process wastage such as thread breaks and trimming.
When a warping order is created, the system can automatically move required yarn from stores to production and trigger an RFQ when available stock is insufficient.
From "How much yarn do we have?" to "How much yarn do we actually need for this warping plan?".
Sizing
The warping calculation and routing logic were extended into sizing instead of creating a separate disconnected process.
The solution adds chemical consumption ratios and per-beam sizing cost, giving the business better visibility into what is being consumed at the sizing stage.
This means sizing is no longer just another production step it becomes a measurable part of the overall fabric cost.
Weaving
Weaving connects the prepared warp with the required weft consumption and production parameters.
Warp and weft consumption are tracked against the BOM, while production output is captured roll by roll instead of as one bulk quantity. For example:
GF-001 → 102 m
GF-002 → 97 m
GF-003 → 105 m
Each roll carries its own roll number, length, weight and production date, creating a much clearer production record.
The system also provides visibility into loom-level efficiency and downtime across the 110-loom operation.
Because 100 metres in the system is not the same as knowing which roll produced those 100 metres.
Two-Way Traceability
Follow the Fabric Forward. Or Follow the Yarn Backward.
The implementation maintains relationships across every major production handoff:
Yarn Lot → Warping → Sized Beam → Weaving → Fabric Roll → Quality Inspection
This creates two-way visibility.
Start with a fabric roll: Where did its yarn come from?
Start with a yarn lot: Which beams, production orders and fabric rolls used it?
Instead of searching through multiple spreadsheets and production records, the production history becomes part of the ERP transaction itself.
Custom Costing Engine
The costing engine is built on Odoo Manufacturing and brings together the actual cost drivers across production. It combines:
Actual yarn consumption
Sizing chemical cost per beam
Labour cost
Operation cost
Warping wastage
Sizing wastage
The result is visibility into cost per roll and cost per metre, based on the production process rather than a simplified standard calculation.
The question changes from "What should this fabric cost?" to "What did this fabric actually cost?"
Accounting in Odoo
Tally was replaced with Odoo Accounting, bringing financial data closer to purchasing, inventory and production.
Production, inventory valuation and accounting now work from one connected data source rather than separate systems.
That reduces the distance between what happens on the shop floor and what appears in the financial records.
Grey Fabric Inspection
Quality checks are built into the production flow rather than treated as an afterthought.
Inspection parameters and tolerances can be configured according to fabric type. Each roll can then be classified as:
Accepted
Rejected
Hold
Rejected and held rolls are moved to dedicated locations so they cannot accidentally enter saleable inventory.
The process also supports downgrade and rework, allowing quality outcomes to remain connected to the actual fabric roll.
"7Span has completely changed how we run the mill. Purchasing, production, inventory, quality and accounting now work on one system instead of paper, Excel and Tally. We can trace any grey fabric roll back to its yarn lot, see wastage at each stage, and know what a metre of fabric actually costs us. The 7Span team deserves real credit. They understood our warping, sizing and weaving process before building anything, and their customisations fit how our floor works. They were responsive and professional throughout, and we'd recommend them to any textile business looking at an ERP software."
Still Running Your Mill on Excel and Tally? Let's Map What ERP Software Can Replace
In a 30-minute call, our Textile ERP team walks through your stages from yarn to dispatch. You leave with a clear list of what Odoo covers as standard and what you'd need custom-built.
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