ASSIGNMENT NO: .

CUT ORDER PLANE:

One of the most crucial activities that takes place in cutting room is Cut Order Plan.

This activity is also termed as ‘lay plan’,  ‘cut plan’,  ‘lay lot plan’, etc. Cut Order Plan is
basically optimizing the cutting process under certain constraints by following certain
parameters.

Marker efficiency, a subset of Cut Order Planning, is much hyped, as it is easily quantifiable
in terms of percentage of fabric consumption. There are many facets to Cut Order Planning,
reducing fabric consumption being just one of them. It demands mathematical optimisation
of competing objectives.
It is interesting to note that ‘size mix in a marker is a mind-boggling permutation and
combination but actually decided by the CAD operator or “cutting master”.

For example:

An order with S/M/L size and maximum 3-garment marker allowed, there are 10 different
options for 3-garment marker, 6 different options for two-garment marker and 3 different
options for single garment marker. While 3L marker is a theoretical option, practically 3L
marker may not be advisable for exorbitant consumption.
Along with optimizing lay plan, one should also calculate fabric utilization based on fabric
roll length available. To maximize fabric utilization, roll length should be numeral multiple of
lay length. The roll allocation to lay is best done using mathematical algorithm subject to
fabric is defect free.
For example:

Lay length of the marker in hand: 6.5 m Fabric roll in hand:

Roll A……………….. 15 m …………….. remainder fabric 2 m [(i.e.15-(6.5×2)]

Roll B……………… 16 m …………….. remainder fabric 3 m [(i.e.16-(6.5×2)]

Let’s take a simple example. You have received an order of 1200 pieces as under:

Colour/size Small Medium Large

Red 66 200 133

Blue 100 300 200

Green 34 100 67

Suppose your existing cutting table length will allow you to make maximum three-garment
marker and you can cut maximum up to 150 layers by your straight knife machine.
First Option

Lay1 : 100 layers (red 66 + green 34) : marker S : M : L

Lay2 : 100 layers (blue 100) :  marker S : M : L

Lay3 : 100 layers (red 67 + green 33) : marker 2M : L

Lay4 : 100 layers (blue 100) :  marker 2M

In first option your “cutting master” decides to cut the total order in four lays using three
different types of marker. Second option has saved both making time and cutting time while
your spreading time may remain almost same.

Second Option

Lay1 : 100 layers (red 33 + blue 50+green 17) : marker 2S : L

Lay2 : 150 layers (red 100 + green 50) : marker 2M : L

Lay3 : 150 layers (blue 150) :  marker 2M : L

Factor of cut order planning:

Cut order planning can be done manually or by computer. New computer technology is
more faster and accurate, support more data on all the variable. As many as 50 different
variables, in addition to fabric information, may affect cut order planning.

Some are below;

 Number of size in order

 Number of color in order
 Number of sizes allowed in marker
 Maximum spread length
 Maximum ply height
 Usable fabric width
 Grain line in pattern piece
 Cost of all processes

The result of cut order planning are cutting orders that direct marker planning and lay
planning. Optimal use of material and cutting system are important consideration in
planning cutting order.
Marker planning:

Marker planning is to determine the most efficient combination of sizes and shades for each
order and to produce the best fabric yield and equipment utilization. One cutting order may
require several markers to optimize marker efficiency.

Lay planning:

Lay planning is the basis of managing cutting room labor and table space. Spreading and
cutting schedule are affected by table length, type of equipment, spread length, spreading
time, and cutting time.

Conclusion:

Based on the production order quantity the Cut Order Plan was made. Assuming necessary
details we calculated fabric consumption, fabric cost and total cost.

REFERENCES:
 https://apparelresources.com/technology-news/manufacturing-tech/cut-order-
planning-the-dot-com-way/
 https://en.wikipedia.org/wiki/Cutting-plane_method
 https://pdodds.w3.uvm.edu/research/papers/others/1936/wright1936a.pdf
 https://apparelmerchandisinglearner.blogspot.com/2019/11/cut-order-
planning.html
 https://www.onlineclothingstudy.com/2021/03/cut-order-planning-making-
economical.html
 https://www.slideshare.net/TejasKrishna2/tap-jury-final
 https://www.slideshare.net/RakibulHasan98/presentation1-68706490