Cut order Plan

Cutting plan example 1

 The contract details are as follows
 Size 10 12 14 16 18
 Quantity 40 90 80 25 25
The constraints on lay dimensions are:
Maximum lay height = 50 plies
Maximum lay length = 4 garments marked
The limit of four garments marked may seem
rather contrived but it allows the concepts to
be explained more easily
 It is useful to determine the theoretical minimum
number of lays required to cut the contract:
 Max no of gmts per lay is 4X50=200gmts
 The no. of gmts required = 40+90+80+25+25

=260 gmts
There fore the theoretical minimum no. of lays
= 260/200 = 1.3
This gives a practical minimum of two lays to
cut the contract – the best that is possible
 Lay 1

Lay 2

The contract details

Size 10 12 14 16 18
Quantity 40 90 80 25 25

The worked solution is:

16 18 12 12 Lay 1 – 25 plies

10 14 14 12 Lay 2 – 40 plies
Cutting plan example 2
 The contract details are follows
 Size 12 14 16 18
 Quantity 100 160 120 60
the constraints on lay dimensions are:
Maximum lay height = 60 plies
Maximum lay length = 4 garments marked
 Theoretical minimum no. of lays required
are:
Max no of garments per lay is 4X60=240 gmts
The no. of garments required = 100+160+120+60
= 440 garments
There fore the theoretical minimum no. of lays = 440/240
= 1.83

This gives a practical minimum of two lays to cut the

contract.
Lay 1 16 16 14 18 Lay 1- 60 plies

Lay 2 12 12 14 14 Lay 2 – 50 plies

 Cutting plan example 3
The contract details are as follows:

Size S M L
Quantity 300 600 400

The constraints on lay dimensions are:

Maximum lay height = 75 plies

Maximum lay length = 5 garments marked
Theoretical minimum no. of lays required are:

Max no of garments per lay is 5X75 = 375 gmts

The no. of garments required = 300+600+400
= 1300 garments
There fore the theoretical minimum no. of lays = 1300/375
= 3.47

This gives a practical minimum of four lays to cut the

contract.
S S S S S Lay 1- 60 plies

M M M L L Lay 2 - 75 plies

M M M L L Lay 3 - 75 plies

M M M L L Lay 4 - 50 plies
COSTING OF CUT ORDER PLAN
– MATERIAL COSTS ( Example 4)
 You have received the following contract:

Quantity 1200
Size A B C D E
Quantity 120 240 480 240
120
Single gmt marker lengths (m) : 2.0 2.2 2.4 2.5 2.6

Other relevant information:

End allowance 3 cm per ply
Maximum number of plies 100
Maximum lay length 10 meters
Cost of the fabric is 3$
Cloth saving on multi-size or multi-garment marker is 5%
1. Determine targets:
Theoretical minimum no. of lays is a little more
complicated as the maximum no. of garments
must be inferred. Since the average length is
about 2.3 m per garment, the maximum
number marked will be 4
Theoretical minimum no. of lays = 1200/4X100
=3
Since quantities are not in multiples of 100,
three lays is an impossibility consequently,
the target must be four lays
2. Consider options
3. Make decision
A A E E Lay 1- 60 plies

B C C D Lay 2- 80 plies

B C C D Lay 3 - 80 plies

B C C D Lay 4 - 80 plies
4. Calculation of material

Marker for lay 1 (2.0+2.0+2.6+2.6) X 95/100 = 8.740 m

Marker for lays 2-4 (2.2+2.4+2.4+2.5) X 95/100 = 9.025 m

Ply lengths
Ply length for lay 1 8.740 + 0.030 = 8.770 m
Ply length for lays 2-4 9.025 + 0.030 = 9.055 m

Lay lengths
Lay length for lay 1 8.770 X 60 = 526.20 m
Lay length for lays 2-4 9.055 X 80= 724.40 m

Material costs
Total length 526.20 + (724.40 X3) = 2699.40 m
Total cost 2699.40 X 3.00 = 8098.20 $