When traveling we know that the quickest and easiest route between two points is a straight line, this thinking should be applied in a workplace. In this example i will show you how to set up a cutting room in order to increase throughput whilst maintaining quality.
In a lot of places a cutting room is overlooked in terms of investment and industrial engineering, factories are happy to invest this time, effort and money in a sewing floor yet totally overlook the fact that the cutting room is a service that supplies the sewing floor. Logically the cutting room MUST be able to produce what the sewing floor can handle.
These simple diagrams will explain how the flow of a cutting room should take place, remember this is almost the same for all product types.
Fabric arrives in the cutting room on an A Frame, it should be pre filled in the warehouse with the fabric and the correct marker and lay slip. The cutting room only needs to hold the fabric that is being spread at any given time. A maximum of two A Frames needs to be allocated per table, the position of the A Frames should be directly behind the table for easy access and monitoring. The replenishment of one A Frame takes place during the course of the day until the daily cutting requirement is achieved.
Table Lengths in your cutting room need to be of a length that allows you to get maximum efficiency for the product you manufacture. Marker lengths and ply heights are taken into account to ensure the tables are utilized.
You should take into consideration the cutting time as well as the spreading time, the object is to have enough table length to contain three spreads. One entering the cutter if CAM is used and one spread waiting, the third is being spread at the same time. As a spread finished cutting the second is pulled to the end of the table for feeding to the CAM. If no CAM is used the spreads are still pulled to to the end of the table for manual straight knife or band knife cutting.
My example shows a table of twenty meters with three spreads in total, six meters by three spreads.
Next step is bundling, in a lot of places i have visited this is a disaster, if not managed correct it can be a monster, so balance of headcount is required in order to keep everything smooth and simple. One thing here is you have to make minimal handling and moving of cut goods. Create a space directly behind the CAM or the spread table where manual cutters are cutting. Make a table along the width of the cutting room (see diagram for “sort & ticket table) this is where all sew-baring is done. Then directly behind this you have another table where you sort the cut goods into bundles.
The best way to deliver cut goods to the sewing floor is in Bakers Trolleys, see below pictures on how bakers trolleys look, also take not that all the cut goods are placed flat in the trolleys not to compromise the fabric in anyway.
Lined up neat and tidy, covers can be used to prevent dust making the cut goods dirty, especially on lighter colours.
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