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Cutting lay by lay, and bundles with barcode tickets

Record each lay with its marker, plies and the rolls it used. Cut books the fabric really used onto the colour's production orders and adds the pieces to the style order. It makes bundles with barcode tickets that operators scan at each sewing station.

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Why it matters

In a garment unit the fabric is the biggest cost, and it is usually accounted for by guess. It is issued in bulk, with consumption worked out at month end. When bundles move through sewing on paper, nobody knows where a bundle is or who stitched it, and piece rates are counted by hand. SmartMy Manufacturing records each lay with the rolls it took and the end bits left. It books that fabric roll by roll to the production orders of the colour. It makes bundles that keep the roll's shade. Operators scan the bundle ticket on the terminal at each station. The bundle's place, the job's good pieces, piece earnings and hourly output come from the same scan.

The problem it solves

Fabric goes to the cutting table in bulk and the consumption per piece is worked out at month end, if at all.
Pieces from two shades end up in one garment because bundles do not say which roll they came from.
A supervisor walks the floor to find where a bundle of 20 pieces has got to.
Piece-rate counts are added up by hand from slips every week.

How it works

Under Textile > Cutting, make a lay for a style order and one colour. Give the fabric, marker length in metres, plies and pieces per bundle (20 to start with).
On Pieces per Ply add each size and how many pieces one ply gives. On Rolls add each roll used, the metres taken, the plies from it and the end bits left.
The lay shows pieces cut, fabric used, metres per piece and end bits as you type.
Press Cut. Pieces by size are added to the style order. The fabric of each roll less its end bits is booked to that colour's production orders by size share. Bundles are made roll by roll and size by size.
Press Print Bundle Tickets. Each ticket shows the bundle number, style order, colour, size, pieces, shade and roll, with a barcode.
Supervisors Issue to Line from the Bundles list. At each station the operator presses Scan Bundle on the terminal; the scan is kept and the pieces count as good on that job.
Press Done on a bundle when it has passed its last step.

Everything it does

Lays

Numbered LAY/00001; style order, colour, fabric, marker length (m), plies, date, pieces per bundle (20 to start with)
Pieces per Ply by size; Pieces Cut per size = pieces per ply x plies
Rolls: roll (lot), shade from the roll, metres taken, plies from it, end bits (m)
Results: Pieces Cut, Fabric Used (marker length x plies), Per Piece (m), End Bits (m)
Cut asks to confirm. It refuses a lay with no sizes, no plies or no rolls, or with a size that is not on the style order
Filter To Cut; group by style order

Fabric booked at actual

Metres taken less end bits, per roll, go onto the fabric line of the colour's production orders, shared by the pieces each size got
Each roll is booked as its own lot, so stock and cost follow the real consumption
A production order with no fabric line gets one; orders already done or cancelled are skipped

Bundles and tickets

Numbered B0000001; made roll by roll (one shade in a bundle) and size by size, up to the pieces per bundle
When rolls have plies, bundles follow each roll's plies; otherwise all bundles carry the first roll
Ticket: bundle number, style order, style, colour, size, pieces, shade and roll, Code 128 barcode, two to a row
Where: Cut, Issued to Line, In Sewing, Done; Last Step; the Scans tab (station, step, operator, pieces, when)
Issue to Line from the form or for many bundles at once from the list
Bundles list: filter Not Done (on to start with), group by style order, last step or where

Scan Bundle on the terminal

Scan with a barcode reader or type the number; a number typed without the B is found too
The scan records station, operator and pieces and moves the bundle to In Sewing
The bundle's pieces count as good pieces on the job of its colour and size at that station, starting the job if needed
So piece earnings, line hourly output and OEE follow the scan
A bundle already scanned at that station is refused

Who uses it

Cutting master or supervisorRecords lays and rolls, presses Cut and prints the bundle tickets.

Line supervisorIssues bundles to the line and finds any bundle by its last step.

OperatorScans each bundle on the terminal at their station.

Production managerChecks fabric per piece and end bits against the costing.

Where you use it

Web: Manufacturing > Textile > Cutting, and Bundles
Shop floor terminal (a web page in a tablet's browser): Scan Bundle, with a barcode reader or the keypad
Printed: Bundle Tickets (PDF)
Not in the SmartMy Manufacturing app: the textile screens are on the web only

What you control

Settings

Textile screens: Settings > Manufacturing > Industry: Textile, per Entity (off to start with)
Pieces per bundle: 20 to start with, per lay
Bundle ticket printer: any printer that prints the PDF; no label printer is set up for it

Works with

SmartMy HRMSPieces counted from bundle scans become piece earnings, which reach the payslip when you also have SmartMy HRMS payroll.

Questions

Does the fabric issue follow what we really cut?

Yes. Cut books the metres taken from each roll, less its end bits, onto the colour's production orders. Each roll goes as its own lot, so stock and cost show what was really used.

Can a bundle mix two shades?

No. Bundles are made roll by roll when you give each roll's plies, so every bundle carries one roll and its shade, printed on the ticket.

Do operators need a phone or a login to scan?

No. They scan on the shop floor terminal, a web page on a tablet at the station, after signing in there with their PIN or badge.

What stops a bundle being counted twice?

A bundle scanned once at a station is refused there a second time. The scan list on the bundle shows each station, operator and time.

Can we print tickets on a label printer?

Tickets print as a PDF, two to a row, with a Code 128 barcode. A layout for a particular label printer is not set up; we can test yours with you before go-live.

Related features

TEXTILE AND GARMENTSTextile: fabric data, rolls and style orders by ratioKeep yarn and fabric details on your items and every roll with its metres, kg, shade and dye lot. Take a buyer's style order by colour and size ratio and make one production order per colour and size in one step.SHOP FLOORThe shop floor terminal: a tablet at each machineA tablet at each machine or station shows its jobs in big tiles. Operators sign in with a PIN or badge, and start and pause jobs. They count good and rejected pieces with a reason, and stop the machine with a reason. Every count goes straight into the order.SHOP FLOORPiece rates, skills and earnings, to HRMS payrollSet a rate per good piece for a step, a machine, an item or a category. Every good piece counted on the terminal earns its operator the rate that applies that day. With SmartMy HRMS, the month's earnings go on the payslip as wages for PF, ESI and tax.LINES AND SCHEDULINGAssembly lines: operation bulletins, balancing and hourly outputSet up each line with its stations, and write an operation bulletin per item with the SMV of every step. See the bottleneck and line balance at once. Each day's line plan becomes a production order, and the hourly board fills from the shop floor terminal.TEXTILE AND GARMENTSCartons and packing listsPack a style order into cartons by a size ratio, colour by colour, from what is cut and not yet packed. Packed adds the pieces to the style order, and the packing list prints with every carton, its sizes and weights.

See your shop floor on it.

Tell us what you make, how many machines and people you run, and how production is recorded today. We will set up a line with you and run a job on the terminal.

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