One roll, from delivery to unit cost.
How a textile manufacturer runs warehouse, production and costing on OYO AI: every roll costed on its own, every consumption booked to the order line that caused it, and nothing edited after posting.
What the manufacturer gets, in numbers.
Every figure here is enforced by the platform, not requested in a manual. Configured on OYO AI, not custom code, so it holds on day one and on day one thousand.
Specific identification, never an average. Three customers cut from one roll carry three true unit costs.
Corrections keep both numbers, reversals write counter-movements. The audit trail is complete by construction.
There is no such thing as material consumed by nobody, so the costing report is right by construction.
Four numbers every morning: rolls on hand, quantity, stock value, and what is still open on the floor.
- 13 business rules enforced automatically
- 3 hands on every delivery: quantities, confirmation, money
- 14-day ageing alert on unsettled transfers
- 0 code changes to alter a tolerance or a label
- 3 languages, one vocabulary
Buy it by the roll. Cost it by the order line.
The manufacturer buys fabric and trim, receives it roll by roll, issues rolls to production, and splits what was actually used across individual customer order lines. Everything else in the system exists to feed that split or to prove it.
A school shirt made for one school and the same shirt made for another carry the same product code and are two completely different cost objects. So consumption is booked against an order line code, never against the product code alone. The line also carries the customer’s own wording, because a code without it is not traceable a year later.
One equation, checked per transfer line.
Tolerance 0.150 kg · 0.500 m · 0 pcs. Out of balance, the settlement goes back to allocation. Nobody can post it away.
Raw warehouse
The sum of every roll’s balance in the raw store. Moved by receipts, transfers out and returns in.
Production zone
What is physically on the cutting floor: the open quantity of the transfers. Moved by consumption, waste and returns out.
Finished goods
Accepted good units by order line. Moved only by an accepted finished-goods receipt.
The chain the material follows.
- 01Customer order line
- 02Production task
- 03Purchase order
- 04Receipt, creates the rolls
- 05Financial approval
- 06Transfer to production
- 07Material request (FIFO)
- 08Cutting marker
- 09Actual consumption
- 10Return · Waste
- 11Finished goods
- 12Cost per order line
Seven groups. They follow the material, not the menu.
Reference data, demand, procurement, the raw warehouse, production, corrections, insight. Twenty-four use cases, each with its main flow, the rules it enforces and the exceptions it handles.
A · Reference data and setup
- UC-01Maintain the material catalogue
- UC-02Define the zones, the locations and the production stages
- UC-03Set tolerances, approval thresholds and the roll label
B · Demand: orders and production tasks
- UC-04Register a customer order and its lines
- UC-05Break an order line into production tasks
C · Procurement and receiving
- UC-06Raise a purchase order and get it approved
- UC-07Receive a delivery: three hands, one document
- UC-08Return material to the supplier and correct the receipt
D · The raw warehouse
- UC-09Read a roll’s balance
- UC-10Issue material to production
- UC-11Correct a roll’s physical balance
- UC-12Count the stock, one warehouse or two
E · Production
- UC-13Ask for material, and let FIFO choose the roll
- UC-14Build the cutting marker, where planned waste is born
- UC-15Book actual consumption against order lines, and close the transfer
- UC-16Return the good remainder to the store
- UC-17Register waste, and keep abnormal loss off the order
- UC-18Hand over the finished goods and accept them
F · Corrections and reversals
- UC-19Correct a posted document without erasing history
- UC-20Reverse a posted document
G · Insight: reports, dashboards, audit
- UC-21Answer “what did this order line cost?”
- UC-22Trace one roll from the delivery note to the finished product
- UC-23Start the day on the dashboards
- UC-24Prove who changed what
Six roles. Only one of them sees money.
Director
Adjusts price and exchange rate, adds landed costs, approves everything that touches value.
Approves: Financial approvals, abnormal waste, counts, corrections, reversals
Warehouse keeper
Weighs what arrives, confirms quantities, issues to production, accepts returns, counts the stock. Never sees a price.
Approves: Received quantities, finished-goods acceptance
Production chief
Approves material requests, allocates actual consumption to order lines, runs the production tasks.
Approves: Material requests, consumption allocation, which roll is opened
Cutting room
Raises the material request and enters the marker: sizes, spread, actual usage and waste.
Operator
Limited data entry. Can be delegated the right to correct a roll’s balance later.
Administrator
Users, roles and the reference data: materials, zones, tolerances, labels.
Thirteen refusals, each with a message.
No consumption without an order line
There is no such thing as material consumed by nobody. The form refuses the line.
Nothing is edited after posting
A correction version keeps both numbers; a reversal writes counter-movements. Neither deletes anything, and both end with the Director.
Four eyes, by the system
The person who submitted cannot be the person who approves. Post and Reverse are gated by state and role together.
The status is never typed
It is the record of which button was pressed, by whom and when. Typing it would destroy the history the costing depends on.
Provisional cost never leaves the store
A roll cannot be transferred to production until the Director has approved the financial part of its receipt.
Abnormal loss stays off the order
Waste above the marker’s plan needs a reason and an approval, and is reported as its own loss so one order never pays for another’s.
FIFO proposes, the chief decides
The keeper does not pick a roll freely. Opening a roll out of FIFO order needs a stated reason.
Snapshots at posting
Material and product wording are frozen on every consumption, so renaming a product next year cannot rewrite last year’s cost.
Roll R-000245, as the system holds it.
Not an illustration: the movements of one roll, read off the roll movement card. Ten kilograms in, split across three order lines, half a kilogram wasted, half a kilogram returned at zero cost.
| Date | Movement | Zone | In | Out |
|---|---|---|---|---|
| 05-18 | Receipt | WH-RAW | 10.0 | |
| 05-22 | Issue to production | WH-RAW | 10.0 | |
| 05-22 | Receipt at production | WH-PROD | 10.0 | |
| 05-27 | Consumption, order line 1 | WH-PROD | 4.0 | |
| 05-27 | Consumption, order line 2 | WH-PROD | 3.5 | |
| 05-27 | Consumption, order line 3 | WH-PROD | 1.5 | |
| 05-27 | Waste | WH-PROD | 0.5 | |
| 05-28 | Return to the raw store | WH-RAW | 0.5 |
10.0 = (4.0 + 3.5 + 1.5) + 0.5 + 0.5 + 0. The transfer closes itself, three customers carry three honest costs from one physical roll, and the auditor can read it top to bottom.
Get the full use-case specification.
The complete document, written from the screens: every use case with its main flow, the rules it enforces and the exceptions it handles, plus the catalogue and appendices a reviewer needs.
- All 24 use cases with main flows, flow diagrams, rules and exceptions
- The business-rule catalogue and the requirement-to-test traceability matrix
- The screen index, the status vocabulary and the document numbering scheme
Also read the greenhouse management use case: From crop plan to invoice, on one governed model.