7 Essential Checkpoints for the Cutting Department Before Starting Bulk Cuttin
The cutting department plays a vital role in ensuring that fabric is utilized efficiently and garment pieces are cut accurately. Any errors made in the cutting process can lead to significant material wastage, production delays, or quality issues. To avoid these pitfalls, it’s crucial that the cutting department adheres to specific checkpoints before initiating bulk cutting. This article outlines seven essential checkpoints that every cutting department should follow to maintain precision, minimize fabric loss, and boost overall efficiency.
1. Fabric Inspection and Relaxation
Before any cutting takes place, the fabric must be thoroughly inspected. The goal is to identify defects like stains, holes, or color variations that could affect the quality of the final garment. The fabric should also undergo a relaxation process. This step is especially important for knit and stretchy fabrics, which tend to contract or expand after being rolled out. Relaxing the fabric for a certain period (usually 24-48 hours) allows it to stabilize, ensuring more accurate cutting and better consistency in garment sizes.
Key Points:
– Inspect fabric for flaws like snags, stains, or inconsistencies.
– Ensure the fabric is relaxed for the required time to minimize shrinkage or expansion during cutting.
2. Marker Approval
A marker is the blueprint for cutting fabric efficiently. It consists of a layout of pattern pieces that are arranged in a way that optimizes fabric usage. Before cutting begins, the marker should be thoroughly reviewed and approved by the cutting manager. Markers are either created manually or using CAD (Computer-Aided Design) software, with the goal of reducing fabric wastage while ensuring pattern integrity. Accurate marker planning also helps to maintain consistency in the garments being produced.
Key Points:
– Ensure the marker has been reviewed and approved.
– Check that the marker is aligned with fabric grain and layout specifications.
3. Splicing and Overlap Verification
Splicing refers to the technique of joining two rolls of fabric together to form a continuous piece. When fabric rolls are spliced, the joints need to be carefully examined for any misalignments, overlaps, or gaps. These imperfections can affect the overall quality of the cut fabric and lead to defects in the final garments. Proper splicing techniques and ensuring seamless fabric joints are critical for smooth cutting.
Key Points:
– Check that splicing is done correctly to avoid overlaps or gaps in the fabric.
– Ensure spliced areas are properly marked and adjusted for cutting accuracy.
4. Fabric Alignment and Grainline Check
Fabric alignment is another crucial aspect that determines the final look and fit of the garment. Ensuring that the fabric grainline is aligned with the marker pattern is essential for the garment to drape and fit properly. Misaligned grainlines can cause distortion, twisting, or poor fit in the finished product. Additionally, the fabric should be laid out flat, without wrinkles or folds, to prevent inaccuracies in cutting.
Key Points:
– Confirm that the fabric grainline aligns with the marker’s grainline instructions.
– Ensure fabric is laid flat and wrinkle-free before cutting.
5. Cutting Equipment Check and Calibration
Cutting equipment, whether manual or automated, needs to be in optimal working condition before starting bulk cutting. Blades should be sharp, machines properly calibrated, and all equipment should be inspected for any malfunction. Dull blades can cause ragged edges, inconsistent cuts, or damage to the fabric. Regular maintenance of cutting equipment helps ensure precision and reduces errors.
Key Points:
– Inspect cutting machines and ensure they are in proper working order.
– Sharpen blades and calibrate machines to guarantee clean, accurate cuts.
6. Number of Layers and Fabric Tension
The number of fabric layers being cut at once (also known as ply count) can significantly affect the quality and accuracy of the cutting process. Cutting too many layers at once can lead to inaccuracies, especially on the bottom layers. Additionally, fabric tension should be monitored to ensure that the layers are evenly distributed and the fabric isn’t stretched or skewed during cutting.
Key Points:
– Determine the appropriate number of fabric layers to cut based on the fabric type and cutting equipment.
– Ensure fabric tension is even across all layers to avoid distortion.
7. Pattern Piece Labeling and Defect Marking
Labeling pattern pieces is an essential step to ensure proper assembly during garment production. Each cut piece should be accurately labeled with its corresponding size, style, and part name (e.g., sleeve, front, back). Additionally, any defects identified during the fabric inspection should be clearly marked so that these areas are avoided during cutting.
Key Points:
– Label each cut piece with the appropriate information for easy identification.
– Mark any fabric defects and avoid cutting in these areas.
Conclusion
By following these seven essential checkpoints, the cutting department can greatly reduce the chances of errors, fabric wastage, and production delays. Each step, from fabric inspection to equipment calibration, plays a crucial role in ensuring that bulk cutting is done accurately and efficiently. Ultimately, a well-organized and thorough approach to the cutting process sets the stage for smooth production and high-quality garments.
Whether you’re running a small garment business or a large-scale manufacturing operation, paying close attention to these checkpoints will help you maintain high production standards and improve your overall efficiency. If you are looking for a reliable woven fabric manufacturer with sustainability certification, please contact us.
