Fabric loss during spreading: A theoretical analysis and its implications

Minimising fabric loss during spreading can reduce the total production costs of garment manufacturing. Some methods for minimising fabric loss during spreading have been introduced in previous studies, such as guidelines for altering wasteful procedures in a cutting room and regression analysis for prediction of fabric loss. However, splice loss (the loss during joining of different fabric rolls) during the laying-up process is one of the causes of fabric loss, and this has been excluded in previous studies. In our study, assuming that the spreading process is handled in a controlled manner and there are no flaws in the fabrics being spread, a theoretical model is developed for the calculation of fabric loss as a result of splice loss and excessive end loss during spreading. The computation results — the effect of changing the roll length and the effect of changing the number of rolls — are calculated.