Surat has always been at the heart of India’s weaving industry. Thousands of looms run every day, producing fabrics for markets across the country and abroad. Yet, behind this scale, many weaving units face the same daily struggle—too much dependency on manual work, constant follow-ups, production pressure, and very little clarity on what is actually happening on the shop floor.
This is the story of a mid-sized weaving unit in Surat that was doing good business but felt stuck. The machines were running, orders were coming in, but efficiency was not improving. After implementing Texfo, the unit saw a 20% improvement in overall efficiency—not by adding more looms, but by bringing better control and visibility into daily operations.
The Situation Before Texfo
The unit had around 40 rapier and air-jet looms, experienced operators, and regular buyers. On paper, everything looked fine. But inside the factory, problems were slowly building up.
Production was tracked in registers. Supervisors wrote numbers at the end of each shift. If something went wrong during the day, it was usually noticed much later—sometimes after the damage was already done.
Yarn stock was managed based on experience rather than data. Sometimes there was excess yarn lying unused, and other times production had to stop because the required yarn was not available on time.
The owner spent most of his day asking questions:
- “Why was today’s production low?”
- “Which loom was stopped and for how long?”
- “Are we on track to deliver this order?”
Getting clear answers was difficult because information was scattered.
The Real Problems They Were Facing
No Clear View of Daily Production
There was no way to see live production. Loom issues, breakdowns, or low output were reported late. By the time management reacted, the day was already lost.
Frequent Production Delays
Even with proper machines, output often fell short of the plan. Small delays at one stage affected the entire schedule.
Yarn Planning Issues
Because yarn consumption was not tracked properly, planning was mostly guesswork. Emergency purchases became common, increasing costs.
Poor Coordination Between Teams
Sales, production, and inventory teams worked separately. Sales committed delivery dates without knowing actual capacity. Production teams struggled to catch up.
No Data for Decision-Making
Important decisions were based on assumptions and experience, not facts. The owner knew something was wrong, but couldn’t clearly identify where.
Why They Decided to Use Texfo
The owner did not want a complicated system or something meant for large corporates. What he needed was:
- Clear production visibility
- Better control over yarn and orders
- Less dependency on registers and verbal updates
Texfo felt practical because it was built for textile units and matched how weaving factories actually work.
How Texfo Was Introduced in the Unit
Step 1: Understanding Their Workflow
Before using Texfo, the existing process was carefully studied—loom operations, yarn movement, order flow, and reporting habits. Nothing was forced or changed overnight.
Step 2: Digital Production Tracking
Production data started getting recorded digitally. Loom-wise and shift-wise output became visible.
Supervisors could now see:
- Which looms were running well
- Where downtime was happening
- Which shifts were underperforming
Problems were spotted early instead of at the end of the day.
Step 3: Better Yarn Management
Yarn stock and usage were tracked properly. This helped the unit:
- Avoid sudden shortages
- Reduce unnecessary stock
- Plan purchases more confidently
Production stopped depending on last-minute decisions.
Step 4: Clear Order Planning
Orders were linked directly to production schedules. Everyone knew:
- What was being produced
- For which customer
- By what deadline
This reduced confusion and frequent rescheduling.
Step 5: Simple Reports That Made Sense
Instead of long registers, the owner could now see:
- Daily production summaries
- Loom efficiency reports
- Order status at a glance
Decisions became quicker and more confident.
The Results They Started Seeing
A Clear 20% Improvement in Efficiency
Without adding new looms or workers, the unit increased output simply by reducing idle time and improving planning.
Fewer Production Delays
Because issues were visible early, supervisors could act immediately instead of reacting later.
Better Use of Machines
Underperforming looms were identified and fixed. Machine utilization improved across the unit.
Improved Yarn Control
Less money was blocked in excess stock, and production delays due to yarn shortage reduced significantly.
Better Team Accountability
When data became visible, responsibilities became clearer. Everyone knew their role and performance.
Happier Customers
On-time deliveries improved. Buyers noticed the difference and trust increased.
What Changed for the Owner
Earlier, most of the owner’s time went into daily problem-solving. After Texfo, he could finally step back and look at the bigger picture—future orders, capacity planning, and business growth.
Instead of asking multiple people for updates, he could simply check the system.
What Other Weaving Units Can Learn from This
This Surat weaving unit’s experience shows that:
- Efficiency does not always require expansion
- Better systems bring better results
- Visibility and planning reduce stress as much as they improve profits
Small improvements across production, inventory, and coordination can create a big overall impact.
Final Thoughts
The textile industry is changing, and traditional methods alone are no longer enough. This case from Surat proves that when textile units adopt practical, industry-specific solutions like Texfo, they can achieve real improvements without disrupting existing operations.
Texfo helps weaving units move from manual control to organized, data-driven working—one step at a time.
