In my previous article, I elaborated on the 8 Fabric Losses Your Factory Faces Today. These losses in the factory can be minimized by adapting simple practices, to ensure maximum utilization of your biggest investment, the fabric that you buy.
1. Standardise Endloss – Endloss for one lay must be standardised and set to a minimum as per the requirement of lay. This is an essential practice that must be followed on the floor to minimise this wastage. The general standard for straight knife is 0.02m = 2cm.
2. Minimize Plies – There is an endloss at every ply. To bring down the overall endloss, number of plies must be minimized. Minimum number of plies for an order can be calculated using:
Minimum Plies = (Total Order Quantity)/ (Maximum Number of Pieces Allowed In one marker)
For example there is an order of 2488 pieces. The maximum way feasible in marker is 8.
Minimum Plies For This Order = 2488/8 = 311
To ensure minimum endloss, the number of plies must be as close to 311 as possible.
3. Make Markers in cuttable width – Edgeloss, the fabric loss at the width of the fabric can be minimized by making markers in the entire cuttable width of the fabric.
4. Fabric Grouping – In case of variable widths in fabric, group same or similar widths together and make markers for these varying widths of fabric, thereby minimizing edge loss.
5. Roll Allocation – During laying, fabric rolls are picked at random and spread. This results in large number of end bits after the laying of major lays. Associate fabric rolls with lays in such a way that minimum end bits are left.
6. End Bit Planning – End bit management and taking into account the end bits in the planning itself can reduce the end bits resulting as waste.
Ticket Length Loss
7. Complete Checking Of Rolls – Completely check all fabric rolls for length. This ensures no surprises on the cutting floor and effective fabric control.
8. Vendor Management – Fabric received in the factory should be tracked vendor wise. Vendor wise tracking enables the management to tab the vendors giving less fabric and make informed decisions for the future.
With these measures, it is possible to minimize the wastage on your factory floor effectively.
Know more ways to reduce fabric losses?
Comment below to share your knowledge.
Subscribe to stay updated with the latest trends in the garment industry.