Garment manufacturing is a vast sector. One of the biggest challenges faced by the manufacturers is the optimum fabric consumption. Fabric accounts for almost 70% of a garment’s cost. Hence, reducing even 1% fabric wastage can lead to huge differences in the profit margins.
End-bits are pieces of fabric that are left after spreading a fabric roll. To understand more about the term, click here.
If not managed properly, these end-bits will keep on piling, hence leading to a higher cutting room wastage.
To understand further, let’s take an example of Factory ‘A’, and Factory ‘B’. Factory ‘B’ does end-bit planning, and Factory ‘A’ does not do end-bit management.
Wastage data for these factories are:
End-bit management and planning accounted for a difference of 1% in overall wastage between Factory ‘A’ and ‘B’. The fabric is considered wasted when it is not converted into a useful garment.
Let’s take the previous example to understand the impact of end-bit in terms of fabric cost:
Factory A is losing 4% more than Factory B, due to higher end-bit wastage.
Now that we have established the importance of end bit management, let’s dig deeper into finding the methods of proper end bit utilization.
End-bits are generated due to four main reasons:
Now, end-bit generation is inevitable, but end-bit management can be done at the cutting end.
There are different ways that can help a factory in end-bit management. A few of them are mentioned below:
Following all these practices will bring discipline to cutting floor. To ensure that these practices are followed on-floor, work allocation should be done accordingly.
But, end-bit management is the first step towards its reduction. The second step would be utilizing these end-bits, i.e., by converting these end-bits into useful garments.
To understand end-bit planning, let’s understand the following:
Total End-bits generated on-floor: all the end-bits that are greater than or equal to the BOM consumption.
End-bit planning becomes crucial when the end-bit quantity becomes difficult to handle on-floor.
End-bit planning should be done, when the Fabric Reuse Opportunity and balance quantity to cut becomes equal.
To do the end-bit planning, an account of total end-bits on-floor should be maintained with the planner. Also, end-bit planning based on the predicted end-bits will not give an efficient plan.
To cater to this problem, a system should be put on the cutting floor that would keep a live account of end-bits being generated on-floor.
IntelloCut is a software which gives a real-time account of actual end-bits being generated on-floor in terms of length and pieces. This information would help the planner in end-bit planning using the on-floor data captured by intelloCut.
Planning the order quantity based on the end-bits generated on-floor is beneficial in case of smaller order quantities, as the end-bits generated will be less. In case of larger order quantity, end-bits will keep piling.
To understand this, let’s take an example of an order with following lay-plan.
Let’s assume, that on an average, every lay gives 5-6 end bits. So, after completing 10 lays from the longest marker (M-1), there will be a total of 50-60 end-bits on-floor (see image below). Managing these end-bits can be difficult.
In this scenario, after completing 2-3 lays from the biggest marker, one short marker should be laid simultaneously using the end-bits generated from M-1, in this case. This will help in reducing the total end bits generated on-floor.
This practice would help in an efficient end-bit utilization, reduced effort in sorting end-bits, and reduced wastage.
If we go into the business value of this technique, then it can show huge results in better utilization of fabric and hence the money spent instead of just wasting it.
Intellocut is a software that gives real-time data on the lays completed on-floor and the end-bits generated from the completed lays. This data can be extremely useful to help in managing and better planning of these end bits.
Do you know of more ways to better manage end bits on-floor? Please share in the comment box below.
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Ramandeep is a Consultant at ThreadSol. She is a Fashion Technology graduate from National Institute of Fashion Technology, Bangalore and has more than 2 years of experience in Apparel Manufacturing and Consulting.
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