8 Ways To Minimize The Fabric Losses In Your Factory

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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.

Endloss

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.
Hence,
Minimum Plies For This Order = 2488/8 = 311
To ensure minimum endloss, the number of plies must be as close to 311 as possible.

Edge Loss

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.

EndBits

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.

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8 Comments

  1. RF Cooke says



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    Thank You for your reply Mausmi, I am from the old school and things have changed a lot now. We had a Levi Plant in Australia in the late 70’s. The factory floor contained 400 very well trained people, our people.
    I dislike all this computer crap everyone seems to want these days, with exception of a few machines.
    We managed to be the best Levi Strauss plant in the world and I can tell you why.
    From the time the 1st layer of 14oz denim hit the cutting table, to the end of our production line was 9.5 minutes. We were set up to make one thing, 5 Pocket Western Levi Jeans.
    I understand this has changed a lot since then, however there are still some old Senior Management Levi Strauss guys around that can show the best way to produce a product.

    Ex Levi Strauss International Training Manager Mr. Sam Meeks has evolved to “Pod Cell” production making Tailor Made Jeans. He has done a magnificent job looking to the future and has spent over 20 years in many countries.

    The most respected production person alive.

    Why not you all send him an email ? sam@@tailormade-jeanswear.com

    Yours Sincerely
    Richard.

    1. Mausmi Ambastha says



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      Hi Richard,
      Thanks a lot for the connect. I would be glad to get in touch with Mr. Meeks.
      As far as technology is concerned I would disagree with you looking at the state of industry around me. Do let me know when you plan to visit any country in South East Asia. One visit to a factory should be enough to change your opinion.
      Do plan a holiday here, there are lots of other interesting places to see apart from garment factories.

  2. chamara Wijeratne says



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    This is very good but you missed below 4 important things in fabric savings.
    1. Cut order planning
    Your marker ratios you have to plan efficiently which given the maximum fabric utilisation. The longer the marker higher the fabric utilisation is true in most cases but not always. Some times special ratios given the best utilisation and you have to do the calculation accordingly.
    2. Pattern engineering.
    Where reducing one mm of seam eelowanse or some times you can use selvage specially in molding pcs or which cut out from Overlock machine you may able to save lot.
    3. combine markers
    Make markers with two styles might give a very good results.
    4. Step markers
    You can save end allownace.
    I have a detail presentation regarding material saving with examples and the mathematical formulas for calculating best ratios which is give better result than ” Lectra – Optiplan”
    Which help to save $ 500000 per year in one of garment factory in SriLanka.

    1. Mausmi Ambastha says



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      Hi ChamaraWijeratne,
      I agree that there are lot of other ways that help in saving fabric and requires detail training of the planner and should be followed on factory floor to achieve final results. These are more dependent on individual factory cases.
      I would like to emphasize that even the best marker ratios and cutplan fail if the fabric rolls are not taken into consideration and planned properly. Cut order planning does not ensure actual on floor fabric saving as shown in my article http://stitchdiary.com/are-you-wasting-fabric-in-cutplan/.
      Congratulations that you have developed a logic which gives better markers. It would be great if you can share it with world.
      As per my experience people who have worked in the factory for many years on similar products are always able to find very good marker ratios based on their experience of marker making. But this makes processes people dependent. A good system should be able to take input of these experienced planners and use it to create a further better cutplan. Our product intellocut does exactly that.
      http://threadsol.com/solutions/intellocut

  3. Richard says



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    Dear All, this lady is no fool. It is hard to see exactly where savings can be made without actually seeing the cutting room in question. I have always worked out the metre’s per unit on a lay, second there is no mention of “splice points”, then there is the way the stencil is made AND how good the fabric supplier is at giving you say, 20 x 500 metre 14oz rolls of denim in the same die lot. Regarding end waste it is possible to cut rather than fold the ends of a lay, this can be done quicker than the folded ends in some plants. If you are able to cut lays of 60 pair of denim (120 plies) then it is advisable to as some factories to make 60 pairs into 30 pairs, easy, all you do is sprinkle the half way mark with fine saw dust, this makes it easy to split on the table. One last thing is to measure each roll, make you stencil to fit the most narrow, or group rolls for different lays.

    Richard, Australia.

    1. Mausmi Ambastha says



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      Hi Richard, Thanks a lot for stopping by. Yes indeed there are various other pointers that can be looked into while trying to apply the concepts of material utilization. I would try to cover as many parameters as possible in the subsequent articles.
      It would be great if we can have the opportunity to publish some of your knowledge in an article as a guest post. There are very few people who have such in depth understanding of cutting concepts. It would indeed be an honour.

  4. Mausmi Ambastha says



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    Hi Ashok,

    The CNC cutting machine works on an endloss of 2cm to 6cm. But it mostly depends on the kind of fabric being used. The best I have seen is 1cm, which is being used in Raymond’s Siver Spark. This is over trouser and suit materials. However, it requires a lot of effort in terms of discipline and laying team control to achieve this. Fabric stability also plays a role in determining the endloss of CNC machine.

  5. Ashok Kumar says



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    Maam i want to know how much is the general standard for the CNC cutting machine can it be reduced to 0.02m( 2 cm) too.

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