These factors compete with each other, and normally require great experience and skill to produce the best results. The labour required to do this is therefore expensive.
The above functions are de-skilled and simplified in this system, we use a system of percentages, developed over many years, combined with the power of the computer the Cut Planning procedure becomes an easy task and will be able to be performed by personnel with much lower skill levels. More importantly it is simpler to achieve the main goals of the planning procedure. Marker Plans are sent to the “Marker Making” this function is outside the scope of this system; information from this procedure is entered into the system, i.e. marker length, efficiency and perimeter length.
2. Markers for linings/Fusible ect.
When main fabric markers have been decided, copy the marker plan into the other fabrics, enter the marker lengths and the system will calculate the requisitions for these fabrics, it will also allow the user to combine sizes, and colours if necessary.
3. Fabric Requisitions
After marker making, the marker lengths are entered and fabric requirements are calculated. A comparison between “Costed fabric requirement” and “Marked fabric requirement” is made, showing potential profit or loss before fabric is issued. Management can now decide in advance what actions are necessary to maximise profit.
4. 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” with the rest of the order. This is automatically proportionally allocated over the whole order, ensuring that excess cloth is not put onto the last (and in most cases the one with the poorest fabric utilisation) as has been being done in the past. It is of course possible to return fabric to stock if necessary.
5. Binding Requirements
It is important that garments that require binding in the same fabric have the quantity properly calculated, so that cutting too much does not create waste. The program will calculate binding requirements.
6. Laying up
When the user is satisfied with the “Marked Rating” the system will produce “Laying up” sheets. These indicate the number of plies of each colour of fabric that should be layed to complete the requirements of the order. These sheets require the operator to enter the following details:
Roll Number: Number of Plies: Damaged lengths of Fabric: off cuts: Remnants: and Joins.
Laying up information can also be entered using “Touch Screens” and “Palm Pilots” This allows information to be collected on a “Real Time” basis.
From this information, complete fabric reconciliation’s can be computed.
7. Fabric Reconciliation
This contains the following information: -
- Fabric issued - Total layed up
- Damaged fabric - off cuts and Joins
- Variance on Manufacturers roll length Profit or loss on order
- Comparison of “Achieved” against “Costed” rating
8. Reports from the system
The following reports are available.
- “Management Report” showing Cutting room profit or loss for the period requested.
- Work in progress. Details of where all order are and their progress throughout the department.
- Garment Numbering. This is a system used in the industry to eliminate garment Shading.
- Bundle List. This is a list of the bundles required in the sewing plant. This is integrated into the Pro-Man system.
- Fabric Performance this informs management everything about the fabric supplier.
- Cutting order summary
- Marker plans
- Fabric requisitions and Issues
- Work in Progress
9. System set-up
Each individual company circumstances are taken into account as follows:
- Table Length
- Cut quantity variance allowed
- Maximum lay height allowed for differing fabric types
- Min/Max Bundle size allowed.
- Computerisation requirements.
10. Pictures
We provide the facility to see pictures of the fabric and styles to be used on the order together with fabric’s r colour ways. This will assist in the elimination of costly errors and avoid the time required for searching for samples
Pro Cut SMV Overview
Monitoring cutting room productivity is not done in most factories, however, many times poor work supply from the Cutting Room causes major production losses. It is essential to factory performance that the cutting room is intelligently managed and controlled and with this in mind we have, through our considerable expertise, developed Pro-Cut-SMV. It is a fact that different styles have a great effect on the cutting room’s ability to supply sufficient work, for example:
Some styles have lots of fusing, -- can the fusing department cope? How do you manage the workload when producing checks or stripes? What is the effect of small orders? How can you balance the work properly to satisfy the demands of all of the production lines? All these questions can be answered using Pro-Cut-SMV.
In conjunction with our Pro-Cut system we are now able to establish a database of ‘Standard times’ for all operations within the cutting room and to monitor Work in Progress throughout this department.
Pro-Cut-SMV was developed to:
- Monitor the performance of all departments within the cutting room
- Monitor Work In Progress
- Make sure that all component parts to an order are cut together
- Simplify time and method study practices for Cutting operations
- Overcome the difficulties of producing accurate Standard Times
How it works
- Studies are carried out on every activity for all processes in the cutting room.
- A sequence of operations required for the style is developed.
- A “Data Card” containing details of the style is set up.
- After marker planning the details are available for marker length, plies, number of sizes etc.
- The above information is then used to generate standard times for every activity.
- Bar-coded tickets are produced for every operation. These are scanned at regular intervals (2 hourly) during the day.
We are then able to monitor performance for the following processes:
- Laying-up
- Straight knife cutting
- Round Knife cutting
- Band knife cutting
- Fusing
- Re-Cutting
- Re-laying
- Matching Stripes and blocks
Numbering
Sorting
Times are established well in advance using Pro-Cut SMV and by using the techniques developed in our Pro-Man system we are able to produce bar-coded tickets giving the required information for the control of the labour force and Work in Progress in this department.
Advantages
- Management decisions based on the current situation not history.
- Reduction of data collection personnel.
- Freeing supervisors and Managers to manage.
- Control of Labour ratios to ensure accurate recoveries.
- Part of a totally integrated production control system.
- Links and other applications.
- Better and more efficient data flow between systems and departments.
- Better trained and more informed personnel.
- Quicker reaction to customers needs.
- Improved customer satisfaction.
- Improved communication.
- Total Work in Progress Control.
- Simple for operators to understand.
- Quick and accurate.
- Print what you require only, it may be the case that some of the reports are used intermittently.
- Transport information into Spread sheet applications.
- It is easy to learn and apply.
- Monitors cutting room efficiency.
- Produces accurate production figures for all functions automatically.
- Monitors WIP.
- It will improve production planning and control procedures.
- Work-in-progress feedback is earlier and is accurate.
- It will lead to accurate style costing for cutting operations.
- Can calculate the time it will take to cut an order.
- Can establish cutting costs for new orders.
- Can establish a cost per unit for cutting different order quantities.
- Can plan the cutting room more effectively.
- Will make you aware of cutting overload before it happens.
- Proper targets can be established for each function within this department.
- Inefficiencies will be easy to identify.
- Automatic emails to head office.
- All of the above points lead to better management control and considerable cost savings.
Reports from the system
The following reports are available.
- Efficiencies of all departments within the cutting room
- Work in progress at all stages per lay per cut.
- Planned lays per order and the position of each one.
- Cutting room output for each department.
- Departmental labour requirements for each order.
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