Running a knitwear manufacturing facility is a balancing act of precision, coordination, and speed. Even with state-of-the-art machines, skilled teams, and strong buyer demand, many factories still fail to achieve profits. The reasons are rarely about capacity. The true problem lies in a lack of clarity.

In various factories, production data is scattered across notebooks, spreadsheets, and verbal updates. If even one stage stalls — like a yarn delivery delay — the entire workflow slows down. This is where the Enterprise Resource Planning (ERP) system comes in. But not just any ERP — generic ERP systems treat knitwear like every other manufacturing business, ignoring its unique challenges. Recognizing this gap, AstraSoftech built KnitOne — a tailored ERP for knitwear manufacturers. 

In this blog, we will dive into the details of why KnitOne ERP was built for knitwear manufacturing. 

7 Reasons KnitOne ERP was Developed Exclusively for the Knitwear Industry 

Here are the top seven reasons that clearly explain the evolution and function of KnitOne for the industry. 

1. Bring 99% Accuracy in Sampling and Costing 

In the knitting manufacturing industry, sales teams play a key role. With their years of experience, they are able to estimate highly accurate yarn usage for sample designs and bulk orders manually. However, to avoid bulk production disruptions, they tend to buy more material. The guesswork often leads to yarn overbuying, which can translate to an average annual loss of $150K. Interestingly, only about 5% of the factory owners know about this massive loss. 

Let’s take an example:  

A jacquard knitted sweater is made with a blend of 70% Merino wool and 30% contrast viscose yarn. For a medium-sized jacquard sweater, around 2.6 kg of yarn is needed. Despite that, 2.8 kg to 3kgs of the yarn is purchased in order to buffer against wastage.  

With a solution like KnitOne ERP, yarn overbuying can be permanently eliminated. The system learns from production data and eventually provides 99% accurate costing for any style and size. This level of accuracy not only significantly reduces wastage but also optimizes purchasing decisions. 

2. Handle All Types of Yarn Issues  

Yarn—regardless of type—is the foundation of knitwear manufacturing. In luxury knitwear production, cashmere is the preferred choice, but its high cost demands precise handling. When control slips, profits quietly erode—shortages delay production; lower-grade yarns replace premium ones, and untracked returns go unnoticed. Gradually, these small inefficiencies add up to a significant margin of loss. 

KnitOne addresses upfront and hidden yarn usage and losses with its Yarn Inventory Solution. It tracks every movement of yarn—whether for a sample or a bulk order—from purchase to return. With this solution and relevant reports, business owners can get clarity and make decisions to safeguard margins. 

3. Offer Defined Manufacturing Timelines 

In many knitwear factories, production begins with a rough two-month plan, often made on spreadsheets. There’s little clarity on which orders to prioritize, or which styles should go on which machines. When changes come in—from buyers or sample approvals—the updates aren’t tracked in real time. This leads to confusion on the floor, overbooked machines, and last-minute rushes to meet delivery dates. As a result, quality drops and deadlines are often missed. 

KnitOne resolves these planning gaps with its Production Planning Control (PPC) Solution, allowing production heads to set a clear schedule from material readiness to final delivery. Knitting machine utilization can be planned, which ensures balanced workloads, scheduled downtime, and smoother production flow. 

4. Access Buyer-Driven Profit/Loss Details 

Profit in knitwear manufacturing comes from buyers, but knowing exactly how much each order earns is often a struggle. To get reports on profit against investment, managers must extract data from multiple sources, merge countless files, and double-check for errors. It’s a slow, manual task where mistakes are easy to make. By the time the numbers are ready, the window for quick action has often passed. 

KnitOne’s Order Balance Sheet (OBS) Solution highlights the contribution of every order. In simple terms, contribution shows how much an order helps cover business costs and generate profit. OBS tracks all related expenses—yarn, labor, machine time, rework, and logistics—to reveal each order’s true performance. With this clarity, leaders can focus on profitable clients, address underperforming ones, and protect overall margins. 

5. Identify and Reduce Multiple Types of Frauds 

In knitwear factories, fraud often hides in the day-to-day processes of inventory, procurement, and production. Some of such frauds are: 

• Issuing of a few extra yarn cones without a record 

• Yarn return is recorded but never sent back 

• A smaller yarn delivery is accepted without checking 

• The yarn purchase price has changed 

• Favoring preferred vendors without merit 

• Worker fraud 

KnitOne understands the risks of fraud and offers effective solutions for material storage and inventory control. Its Inventory Solution records every yarn and material movement in real time, while the Procurement Solution enforces approvals, verifies deliveries, and tracks vendor performance. This combination closes loopholes, prevents false reporting, and keeps the factory’s resources working for profit, not loss.  

6. Provide Better Sales Visibility 

In many knitwear factories, sales processes depend heavily on manual follow-ups. To answer a client’s question about their order, sales teams often have to call or visit different departments. If the relevant person is busy or away, the update can take days. Billing is equally slow, with every detail — taxes, discounts, payment terms — checked and entered by hand. 

The Sales Management Solution in KnitOne efficiently handles both order tracking and billing. Sales teams can instantly see the progress through SFG Movement Tracking. A quick QR scan shows the exact order status, helping sales teams respond to clients instantly. Billing is also simplified as detailed reports with all taxes and multicurrency information generated automatically. The result is better communication and stronger relationships. 

7. Reduce People Dependencies in Factory Operations 

In many knitwear factories, every step depends on the timely exchange of information. If someone is absent or slow to respond, approvals and updates are delayed. This constant reliance on individuals slows the entire process and risks missing deadlines. 

KnitOne replaces people dependency with system dependency. By connecting sales, costing, inventory, production, and delivery in one system, information moves instantly, and tasks trigger automatically. All departments work through role-based access on a unified platform. Work continues without waiting for a specific person, ensuring uninterrupted workflow and consistent output. 

A Must-Know Fact 
KnitOne has already been tested and trusted by Nepal’s luxury knitwear brand Tricot. Go through our case study to learn the journey of how Tricot achieved clear operational visibility and better planning through KnitOne.

Final Thoughts 

Paper logs, endless chasing, and hidden costs are holding knitwear factories back from true growth. The fix is a digital transformation tool that fits your industry. That’s where KnitOne ERP comes in — solving costing mistakes, plugging yarn leaks, streamlining manufacturing flow, preventing fraud, and improving sales visibility. With all operations connected, your factory runs faster, smoother, and gains far greater control over profitability. 

In short, KnitOne is the only reliable ERP solution that offers managers information from yarn to growth, all in one view. 

If you’re ready to simplify your operations and grow your knitwear business with confidence, it’s time to choose KnitOne. 

Why wait? Boost Profits with KnitOne’s Complete Operational Visibility.