Basic HTML Version
The Textile Magazine
APRIL 2012
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73
calculations.
One operator in each production site would then plan
the cut order according to the fabric delivery and the
printed-out Excel sheets. The system was time-con-
suming and prone to error, and it was heavily reliant on
guesswork and approximated estimations. The lack of
automation throughout the manufacturing chain meant
that nearly the entire process had to be performed manu-
ally. The result was sometimes too much fabric, some-
times not enough, halted production, unused cutting
machines, last-minute outsourcing to other companies,
and, in an effort to get the best product yield from ex-
cess fabric, thousands of overstocked jeans that ended
up getting stored in the warehouses and occasionally
sold to employees at cost.
Lectra’s cutting room combination
Lectra’s solutions specialists evaluated Arvind’s
process and concluded that the company should plan
and optimize production orders centrally using Lec-
tra’s Optiplan Expert in combination with its automatic
marker system, DiaminoFashion. The amount of fabric
necessary for each order was reduced, and the amount
of fabric ordered became precise – a two-way gain on
fabric use, with waste dropping to a strict minimum.
Furthermore, overstocks were eliminated, meaning 100
per cent of the products were being delivered to custom-
ers for profit.
In addition, the powerful combination of Diamino-
Fashion with Optiplan Expert meant that Arvind was
able to maximize efficiency based on expert planning
that takes markers, orders and fabric availability into
consideration. Through Lectra’s solutions, Arvind was
able to not only see each marker individually, but see
Mr. Anil Kumar,
CAD Manager
Mr. Ashok Chandru,
Head of Operations
finishing