DATABASE MANAGEMENT FOR APPAREL

BUSINESS

Submitted by,
Submitted to,
Onyfa Thulasi G
Prof. Dr. Amar Tewari
Supraja T
INTRODUCTIO The cutting management system in garment manufacturing factories
is a highly efficient process that involves several sequential stages to
N ensure optimal material utilization and precise fabric cutting.

Garment production starts with the cutting process. In this process,

the fabric is being cut into patterns. When large amount of garment
style has to be cut, a lay is created, which consist of many piles of
fabric spread one above the other. Now all the pattern pieces for all
sizes are from this lay.
Once the pattern pieces are cut by the cutting machine, they are then ticketed.
Cut components are group together as per their sizes and taken to the checking
table. Fusing is also carried out in the cutting room itself.

The ticked panels are now sent to the checking department for inspection of every
individual pieces for any objectionable faults. The checked components of one style and
in one size are now clubbed and bundled using tie. This bundle is sent to the sewing
department.

It is an extremely important section of the garment manufacturing process which has a

major impact on the profitability of the business. The cutting room is the feeding point to
the factory has the massive impact on all the further processes of garment
manufacturing.
OBJECTIVES

Precision of a cut U

A proper and a smooth cut

is one of the prime Clean edges Sco
objectives of cutting. If a h
A raw edge of a fabric whi
garment is not cut
often leads to of b
appropriately it may cause snagging or fraying. the
disturbance, chances are it Such defects are a fo
may not fit the body well. result of cre
inappropriately w
Hence, it is significant to sharpened knives. wit
cut the pattern shapes do
accurately. bla
OBJECTIVES

Precision of a cut Unscorched, unfused

Clean edges edges
A proper and a smooth
cut is one of the prime Scorching is caused due to
A raw edge of a fabric
objectives of cutting. If a heat buildup in knife,
often leads to which comes from friction
garment is not cut snagging or fraying.
appropriately it may of blade passing through
cause disturbance,
Such defects are a the fabric. If the piles are
chances are it may not fit result of forcefully separated it
the body well. inappropriately creates snagged edges. A
sharpened knives. well sharpened, blade
Hence, it is significant to with wavy edges slowing
cut the pattern shapes down the speed of the
accurately. blade offers a good edge.
OBJECTIVES

Unscorched, unfused edges

Co
Scorching is caused due to
Clean edges heat buildup in knife, which Support of the lay The
comes from friction of sho
A raw edge of a blade passing through the Cutting should not be
fabric often leads to fabric. If the piles are only provide support heig
snagging or fraying. forcefully separated it to the fabric but also are
Such defects are a creates snagged edges. A allow the blade to fo
result of well sharpened, blade with penetrate the lowest m
inappropriately ply of the spread. hum
wavy edges slowing down
sharpened knives. a
the speed of the blade le
offers a good edge. cau
in
OBJECTIVES

Unscorched, unfused Consistent cutting

edges
Support of the lay The cutting system
Scorching is caused due to should not hold to
heat buildup in knife, Cutting should not only be limited in the
which comes from friction provide support to the height of piles there
of blade passing through fabric but also allow the are many reasons
the fabric. If the piles are blade to penetrate the for same such as
forcefully separated it lowest ply of the spread. mechanical or
creates snagged edges. A human reasons such
well sharpened, blade as toppling or
with wavy edges slowing leaning this can
down the speed of the cause deterioration
blade offers a good edge. in cutting quality.
OBJECTIVES

Consistent cutting

The cutting system

Support of the lay should not hold to be
limited in the height of
Cutting should not piles there are many
only provide support
reasons for same such
to the fabric but also
allow the blade to as mechanical or
penetrate the lowest human reasons such as
ply of the spread. toppling or leaning this
can cause deterioration
in cutting quality.
 FUNCTIONALIT
Y
The cutting department gets the cut order from the production manager. The cutting in-charge
generates a fabric requirement sheet or requisition slip to the fabric store to issue fabrics.

Knitted fabrics require relaxation before cutting. After receiving the fabric from the fabric store, the
cutting department opens the fabric from the fabric roll and lays it on the table for relaxation for
some hours before cutting.

The cutting master plans the number of markers they need to prepare, the size combination to
be set for each marker and the number of plies to be laid in each marker.

Spreaders lay the fabric on a cutting table as per total marker length. The layer height is kept
up to a certain inch.

The cutting master plans marker ways, marker lengths and the numbers of plies to be laid in
each lay. After layering, the marker paper is laid on the top of the layer.
 FUNCTIONALIT
Y Garment patterns are cut and taken out from the layer. These layers are sorted size-wise and
color-wise in bundles. Each ply is numbered using stickers.

To maintain the cutting quality, standard cutting components are checked randomly by quality
checkers. If defective components are found, they replace those defective parts.

As per order requirements, printing and embroidery is done on cut panels. Size-wise sorting is done
after receiving printed and embroidered panels. The checking of printed and embroidered panels is
also done by the cutting department.

Re-cutting is done for garment components that require to be replaced in bundles.

Fusing in garment components is done to stiffen parts of a garment. If needed, fusing is done at
the cutting section.
REQUIREMENT
ANALYSIS: • Pattern specifications and dimensions.
• Grading information for size variations.
• Pattern versions and revisions.
• Cut quantities and sizes required for each order.
• Inspection results for cut pieces.
• Defect tracking and rework information.
• Quality control checkpoints and outcomes.
• Order details (customer, order number, delivery date, etc.)
• Bill of materials (BOM) specifying the patterns and quantities for
each order.
• Bundling requirements for cut pieces.
• Production schedules and deadlines.
• Machine and Equipment Data.
• Material wastage and efficiency calculations.
• Cost data associated with each cut.
• Required cutting plan as per the manufacturer’s requirement
• Data for optimizing material usage and reducing waste.
• Record of past orders to forecast the future requirements.
 Receiving Preparing cut Receiving
Receiving fabric marker from
marker plan ratio
CAD

Preparing
Spreading of Prepare marker Verify fabric
record of lay
fabrics length approval status
details

Laying CAD Cutting the Ticketing Inspection

Marker fabric lay & bundling

To sewing Preparing
department bundling record

FLOW CHART
DATA FLOW DIAGRAM

LEVEL
Requisition slip
is generated
0 Inspection
1.0
Receiving cut order Order details
from production Cutting management Sewing department
manager system
Fabric received
Bundling record
from supplier
 Receiving cut D Receiving marker from CAD 3.0
order details
order from 1 D3 Pattern details
production Preparing
Fabric inventory
manager D2 marker length
data D4 Grading details
Fabric 5.0
1.0 2.0 D5 Style details
verification
Fabric received Preparing lay
Requisition slip status
is generated from supplier 4.0
Fabric
D1 Rejected panel 9.0 D1 Marker
D6 dimensions
Lay records spreading
7 details (reason) Recutting 0
Rework D7 Marker mode
D18 7.0 6.0
information
Ticketing & D8 Spreading mode
Cutting
Approval of Bundling
Sewing panels and
Placement of D9 Fabric parameter
department defect tracking
8.0 CAD marker
If any damaged Inspection D1 D1 Waste & efficiency
Cut data
panels 4 2 metrics
D1 Bundle D1 D1 Machine &
Quality control Cost data
D16 5 record 1 3 Equipment Data
data
 Order Current Buyer Marker Roll Length
Marker
cost status name dimensions ID in yard No. of
length Shade
Lay Order rolls
Buyer Order
No. of length In ID Rolls
ID Order ID Spreading
plies account Fabric in
record
per lay mode of inventory stock
Delivery Order
Date of data
date qty Quantity Price
order Cost per
Pursuant Width of
In to panel Rolls
in yard rolls
accord returned
No. of Fabric Fabric
with Defective
garments consumption Supplier type
Order rolls
per ply ID
Style ID
no Grading No. of No. of Lay
Bundle
info panels plies width Approved
Pattern no
per lay per lay panels
Shade details Style Rejected
Panels
no. panels
for each Panel
shade Cut Order
no
Product Part record ID Rework Quality
ID name info control data
No. of Proceeds
to Current
panels shade Product status
In line per ID Identified
with Product bundles Order defect
ID ID Passed
Total no. Bundle
on to

ER
of record
No. of
bundles Part
Bundle bundles
name style
no per lay
 PRE-NORMALISATION
Entity Attributes Primary key

Order Order ID, Buyer ID, Buyer name, Order qty, Date of order, Order Order ID
cost, Delivery date, Current status
Fabric inventory data Order ID, Product ID, Supplier ID, Supplier name, Roll ID, Qty, Roll ID
Fabric type, Shade, Length in yard, width in yard, No. of rolls,
Price of rolls, Defective rolls, Rolls in stock, Rolls returned
Pattern details Order ID, Product ID, Style no., Part name, Shade, Grading info, Product ID
Marker way, No. of panels in a garment
Spreading record Style no ,Marker dimensions, Marker length, Marker mode, Lay Style No.
length, Max no. of plies per lay, Total No. of plies , Cutting lot
number
Cut record Style no., Order ID, Max No. of plies per lay, No. of panels per Style No.
lay, No. Of garments per lay, of garments per ply, Lay width,
Total no. Of lays, Fabric consumption, Cutting status
Quality control Panel no., Bundle no., Product ID, Total order quantity, Approved Panel No
panels, Rejected panels, Identified defect, Rework info, Current
status
Bundle record Bundle no., order ID, Product ID, Style no, Part name, Shade, No. Bundle No
of bundles per lay, No. of panels per bundle, Total no of bundles
 1st NORMAL FORM
1. Order
Order ID Buyer ID Buyer name Order qty Date of order Order cost Delivery date Current
status

2. Fabric Inventory Data Primary key: Order ID

Order Product Supplie Supplier Qty Fabric Shade Length Width Roll No Price Defective Rolls Rolls
ID ID r ID name type (in (in ID of of rolls in returned
yard) yard) rolls rolls stock

Primary key: Roll ID

Foreign key: Order ID
3. Pattern details
Order ID Product ID Style no Part name shade Grading info Marker way No. Of panels in a
garment

Primary key: Product ID ; Foreign key: Order ID and shade

 4. Spreading record

Style no Marker Marker Marker Lay length Cutting lot Max no. Of Total No. of
dimensions length mode number plies per lay plies

Primary key: Style no

5. Cut record

Style Order Max No. of No. of No. of No. Of No. Of Lay Lay Total Total Fabric Cutting
No. ID plies per panels garments panels panels width length no. no. of consumption status
lay in a per ply per ply per lay of plies
garment lays

Primary key: Style No

Foreign key: Order ID
6. Bundle record

Bundle no Order ID Product ID Style Part name shade No. of bundles per No. of panels Total no. of
no lay per bundle bundles

Primary key: Bundle no

Foreign key: Order ID, Style no.,
7. Quality control Product ID.

Panel no. Bundle no. Product ID Total order Approved Rejected Identified Rework Current
quantity panels panels defect info status

Primary key: Panel No

Foreign key: Product ID and bundle no
 2nd NORMAL FORM
Order
Order ID Buyer ID Buyer name Order qty Date of order Order cost Delivery date Current
status

Primary key: Order ID

1. Buyer info
Buyer ID Order ID Buyer name Order qty Date of order

Primary key: Order ID

2. Order status
Order ID Order qty Date of order Order cost Delivery date Current status

Primary key: Order ID

Fabric Inventory Data
Order Product Sup Supplier Qty Fabric Shade Lengt Width Roll No Price Defectiv Rolls Rolls
ID ID plier name type h (in (in ID of of e rolls in returne
ID yard) yard) rolls rolls stoc d
k

Primary key: Roll ID

Foreign key: Order ID
3.Fabric details

Roll Supplier No of Fabric Shade Length Width Price of Defective Rolls in Rolls
ID ID rolls type (in (in rolls rolls stock returned
yard) yard)

4.Order purchase details Primary key: Roll ID

Order ID Product ID Supplier ID Supplier name Qty Fabric type

Primary key: Supplier ID

Foreign key: Order ID
 5. Pattern details

Order ID Product ID Style no Part name shade Grading info Marker way No. of panels in a
garment

Primary key: Product ID ; Foreign key: Order ID

6. Spreading record No change required

Style no Marker Marker Marker Lay length Cutting lot Max no. Of Total No. of
dimensions length mode number plies per lay plies

Primary key: Style no No change required

7. Cut record
Style Order Max No. of No. of No. of No. Of No. Of Lay Lay Total Total Fabric Cutting
No. ID plies per lay panels in garments panels panels width length no. of no. consumption status
a per ply per ply per lays of
garment lay plies

Primary key: Style No; Foreign key: Order ID No change required

8. Bundle record

Bundle no Order ID Product ID Style Part name shade No. of bundles per No. of panels Total no. of
no lay per bundle bundles

Primary key: Bundle no

Foreign key: order ID; Product ID
No change required
9. Quality control

Panel no. Bundle no. Product ID Total order Approved Rejected Identified Rework Current
quantity panels panels defect info status

Primary key: Panel No

Foreign key: Product ID and bundle no
No change required
 3rd NORMAL FORM
1. Buyer info
Buyer ID Order ID Buyer name Order qty Date of order

2. Order status

Order ID Order qty Date of order Order cost Delivery date Current status

3.Fabric details

Roll ID Supplier No of Fabric Shade Length Width Price Defective Rolls in Rolls
ID rolls type (in yard) (in yard) of rolls rolls stock returned
 4.Order purchase details

Order ID Product ID Supplier ID Supplier name Qty Fabric type

5. Pattern details

Order ID Product ID Style no Part name shade Grading info Marker way No. Panels in a
garment

6. Spreading record

Style no Marker Marker Marker Lay length Cutting lot Max no. of Total no. of
dimensions length mode number plies per lay plies
7. Cut record

Style Order Max No. of No. of No. of No. Of No. Of Lay Lay Total Total Fabric Cutting
No. ID plies per panels garment panels panels widt lengt no. of no. consumption status
lay in a s per ply per ply per lay h h lays of
garment plies

8. Bundle record

Bundle no Order ID Product ID Style Part name shade No. of bundles per No. of panels Total no. of
no lay per bundle bundles

9. Quality control

Panel no. Bundle no. Product ID Total order Approved Rejected Identified Rework Current
quantity panels panels defect info status
 Buyer
Quality
Info
8
Buyer ID 1
RELATIONSHIPS Bundle
record
control
1 *Panel no
*Order ID Order status *Bundle No.
Buyer name 1 Order Bundle no
Order ID
Order qty *Order ID purchase Product ID
1 Product ID
Date of Order qty details Total order
Style
order Date of order quantity
1 Order ID Part name
Order cost Approved panels
Product ID Shade
Delivery date Rejected panels
*Supplier ID No. of bundle
Current status Identified defect
Supplier name per lay
Rework info
Qty No. of panels
Current status
Fabric type per bundle
Fabric Total no. of
bundles Cut record
details
*Style no.
*Roll ID
Order ID
Supplier ID 1
Max No. of plies per
No. of rolls
Spreading lay
Fabric type
Pattern record No. of panels in a
Shade
details garment
Length (in yard) *Style No
1 No. of garments per
Width (in yard) Order ID Marker dimensions
ply
Price of rolls *Product ID Marker length
No. Of panels per
Defective rolls Style No. Marker mode
ply
Rolls in stock Part name Lay length
Lay width
Rolls returned Shade Cutting lot number 1 Lay height
Grading info Max No. of plies per
Total no. Of lays
Marker way lay
Total no. Of plies
No. of panels in a 1 Total no. of plies
Fabric consumption
garment
Cutting status
 THANK YOU.

DMAB Jury.accdb