Cutting Waste Reduction Success: How FabriQC and Monitait decreased 2% of the Apparel Industry wastage

Cutting Waste Reduction Success: How FabriQC and Monitait decreased 2% of the Apparel Industry wastage
Having data of the raw material fabriqc defect map leads to the less wastage in the production

In the fast-paced world of apparel manufacturing, efficiency and quality control are paramount. One company, facing the challenge of reducing waste in their cutting process, embarked on a journey that would revolutionize their operations. With the integration of FabriQC and Monitait, they not only minimize waste but also elevate the quality of their final garments.

The Traditional Cutting Process: Before the intervention of FabriQC and Monitait, the company followed the conventional apparel cutting process. It involved spreading multiple layers of fabric or leather on top of each other according to the spread and cut plans. Designers created patterns, and the length of the cutting layer was allocated accordingly. The fabric rolls were then spread to match the production line's requirements.

The Missing Quality Check: However, what was missing in this process was a crucial quality check. The stages of purchasing, spreading, and cutting had no quality inspection incorporated. It was only after the cutting phase that visual inspection of the batches occurred, typically conducted by humans. This lack of early quality control meant that defects in the fabric could end up in the center of the cut pieces, leading to wasted material and low-quality final garments.

The FabriQC and Monitait Intervention: Recognizing the need for a proactive approach to quality control, the company turned to FabriQC and Monitait. These cutting-edge technologies would not only minimize waste but also enhance the overall quality of their products.

Roll Grouping and Discounts:

spreading manually fabric layers
spread with spreading machine 
  • FabriQC allowed the company to group rolls strategically, optimizing the allocation of grades.
  • This not only reduced the cost but also ensured a discount on certain grades of fabric, further contributing to cost savings.

Defect Placement Adjustment:

Manual cutting layers with scissors
automatic cutting with a CNC machine (Copyright to Gerber Cutting machine)
by using the spreading plan, you can choose the distribution of the cutting part based on the fabric width and your production plan
  • Monitait played a pivotal role in reducing waste by implementing a fabric inspection defect map.
  • By adjusting the cutting plan based on defect locations, they minimized the chances of defects ending up in the center of the cut pieces.

Shade Checking:

  • FabriQC's capabilities extended to shade checking, ensuring that color variations were minimized during the cutting process.

The Remarkable Results: The results of this intervention were nothing short of remarkable:

  • Waste Reduction: The integration of FabriQC and Monitait drastically reduced fabric wastage. Defects were strategically placed along seams rather than the center of the cut, resulting in minimal material wastage.
  • Cost Savings: Roll grouping and the utilization of discounted grades led to significant cost savings in raw materials, directly impacting the bottom line.
  • Quality Improvement: With the defect map in place, the overall quality of the final garments improved dramatically. Fewer defects in the center of cut pieces meant a higher-quality end product.
  • Efficiency Gains: The process became more efficient, with fewer reworks and a smoother flow from cutting to garment assembly.

The success story of this apparel manufacturer serves as a testament to the transformative power of technology in the manufacturing industry. By implementing FabriQC and Monitait, they not only reduce waste and costs but also elevate the quality of their final garments. It's a reminder that innovation and quality control go hand in hand, setting the stage for a more sustainable and competitive future in apparel manufacturing.