Critical Analysis of Material Consumption and Cost Reduction Techniques for the Apparel Cutting Processes

Abstract

Revenues generation in the garment industry is synonymous with material consumption. This study thus analysed material consumption and cost reduction techniques in the Tanzanian garment industry. The research employed quantitative (experimentation) and qualitative approaches (document review and observation technique) in the apparel cutting processes. Experimental results of material consumption from ten tests averaged efficiency of 78.67%, the wasted pieces (19.2%), and unnoticed waste (2.03%). Essential considerations to reduce material waste include: digitalising the fabric cutting processes; providing workers training; deploying appropriate practices in the cutting room (e.g. pattern engineering and pattern accuracy); considering the quality of the procured fabric and fabric efficiencies relative to different human body shapes and proportions; and considering the separation process rather than extending facings, splitting substantial components, slight reductions in a flare, and seam displacements. The study implies that apparel enterprises can benchmark their actual material consumption circa 50-70% of their total garment manufacturing costs.

Keywords: Material waste, Garment industry, Fabric losses, Cost reduction techniques, Small and medium-sized enterprises.