Fabric represents up to 70% of the total product cost and is therefore the single most important component in garment manufacture. It is essential to the success of the business that this, the most expensive component is properly controlled. It is not just a matter of having good markers (although of course this is essential) but also to make sure that fabric is utilized to the maximum

Fabric Receipt

The system starts with the receipt of fabric, on receipt of material we enter all the roll details and produce a minimum of 4 bar codes which are attached to every roll. These bar codes are used to monitor how this particular piece of fabric is used throughout the various processes it follows during manufacture. The bar-codes produced at this point are used for the following processes.

Fabric Examination

We have programmed the 40 point fabric examination procedures into Pro-Cut. Once fabric is received it is examined and the results are entered against that roll and the system will accept or reject the fabric based on score.

Cut order Planning – A revolutionary approach!

Pro-Cut starts at the beginning of Cutting Room procedures, and is called “Cut Order Planning” It is the process of establishing the following:-

  • The best combinations of sizes and colours to produce all the garments in the order minimising the amount of labour required.
  • The best combination of sizes and colours to produce all the garments in the order to get the best possible fabric utilisation
  • Quantity per size / colour- This comes from Style and order entry
  • Marker length or number of bodies required to cut in the lay
  • Variance allowed by the buyer – Normally between 2 %and 5%

Fabric Requisitions

After marker making, the marker lengths are entered and fabric requirements are calculated, these include a laying up allowance and an anticipated industrial wastage factor. A comparison between “Costed” and “Marked” is made, showing potential profit or loss before fabric is issued. Management now have the ability to decide in advance what actions are necessary to maximise profit.

Fabric Issue

It is normally the case that fabric issue is not exactly what is required by the order (due to the various fabric roll lengths. It is not economically viable for the “Raw materials store” to accept small lengths as “Returns to stock” as they stay on the shelves and are eventually sold to a “Jobber” at a very low cost. It is therefore necessary to use the “extra fabric” with the rest of the order. This is automatically proportionally allocated over the whole order maintaining the original ratio ensuring that excess cloth is used to the maximum. It is of course possible to return fabric to stock if necessary.

Fabric Lotting

In many cases the delivery of fabric is not made in one lot, and due to the lack of lead time fabric is accepted in several lots, in many cases the customer demands that each lot is cut separately (and must be cut in the same ratio as the order) this demands that the order quantity is divided amongst the lots and the order quantity is reduced proportionally across all of the sizes, these calculations are performed by the program automatically and the program will choose the best markers to accommodate the quantity that has been delivered. The remaining quantity is recalculated and a new marker plan is produced.

Laying up

When the user is satisfied with the “Marked consumption” the system will produce “Laying up” sheets. These are lists of the number of plies of each colour of fabric that should be laid onto each marker to complete the requirements of the order. These sheets are bar coded and require the operator to enter details such as: - Number of Plies, Damaged lengths, off cuts, Remnants, Joins, Balance, etc under the appropriate column

Fabric Reconciliation

This contains the following information: -

  • Fabric issued, Total laid up, Damaged fabric, End bits, Variance on Manufacturers roll length, Costed consumption, Marked consumption, Achieved consumption, Profit or loss against costed consumption and Dead Stock

Some of the Reports generated

The following reports are available and can be printed “From and to” where required.

  • Cutting room profit or loss for the period requested.
  • Fabric supplier Performance both in delivered quantity and quality
  • Cutting order summary
  • Cut order planning
  • Fabric requisitions
  • Fabric Issues
  • Fabric reconciliation
  • Cutting daily output
  • Consolidated Reconciliations- for a specified period



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