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JAOT

Textile Manufacturing

Overview

Textile manufacturing optimization helps garment and fabric producers minimize waste from cutting patterns, schedule production runs efficiently, and manage inventory across complex product lines. The industry faces unique challenges: fabric rolls have irregular defects, patterns must align, and demand varies by season, size, and color.

Optimizing cutting patterns alone can reduce fabric waste by 10-15%, which is significant when raw material costs represent 50-70% of total production costs in the textile industry.

When to Use This

Best for: Production managers and cutting room supervisors in garment manufacturing who need to reduce fabric waste, schedule dye lots efficiently, or balance production across multiple styles and sizes.

  • Scenario: You manufacture garments in multiple sizes and styles, cutting fabric from rolls, and need to minimize offcuts while meeting demand for each size
  • Industry: Garment manufacturing, upholstery, home textiles, technical fabrics, fashion production
  • ROI: Typical fabric waste reduction of 8-15%, plus 10-25% improvement in production scheduling efficiency

Step-by-Step Walkthrough

1. Define garment patterns and sizes

List each garment style and size combination with its fabric requirement. A medium t-shirt might need 1.2 meters of fabric, while an XL needs 1.5 meters. Include the demand quantity for each.

2. Specify fabric roll characteristics

Define roll width, usable length (accounting for defects), and cost per roll. Different fabric types (cotton jersey, denim, polyester blend) have different properties and costs.

3. Create cutting patterns

Each cutting pattern defines how garment pieces are laid out on a fabric roll. A single roll might yield 8 medium shirts or 6 large shirts or a mix. The optimizer finds the best combination of patterns to minimize rolls used.

4. Add production constraints

  • Minimum order quantities per style/size
  • Color batch requirements (all garments of one color cut together)
  • Machine capacity per shift
  • Delivery deadlines by customer order

Textile Optimization in JAOT Builder

5. Execute and review the cutting plan

The solution tells you how many times to use each cutting pattern and which fabric rolls to cut. Verify that total output meets demand and review waste percentage per pattern.

Example Parameters

import httpx

API_URL = "https://api.jaot.io/api/v2"
headers = {"Authorization": "Bearer ok_live_your_key_here"}

# Minimize fabric rolls used to cut 4 garment types
response = httpx.post(f"{API_URL}/solve", headers=headers, json={
    "variables": [
        # pattern_X = number of times to use cutting pattern X
        {"name": "pattern_a", "type": "integer", "lb": 0},
        {"name": "pattern_b", "type": "integer", "lb": 0},
        {"name": "pattern_c", "type": "integer", "lb": 0},
        {"name": "pattern_d", "type": "integer", "lb": 0},
    ],
    "objective": {
        "sense": "minimize",
        "coefficients": {
            "pattern_a": 1, "pattern_b": 1,
            "pattern_c": 1, "pattern_d": 1,
        },
    },
    "constraints": [
        {
            "name": "small_shirts_demand",
            "coefficients": {"pattern_a": 4, "pattern_b": 2, "pattern_c": 0, "pattern_d": 1},
            "sense": ">=",
            "rhs": 200,
        },
        {
            "name": "medium_shirts_demand",
            "coefficients": {"pattern_a": 3, "pattern_b": 0, "pattern_c": 4, "pattern_d": 2},
            "sense": ">=",
            "rhs": 350,
        },
        {
            "name": "large_shirts_demand",
            "coefficients": {"pattern_a": 0, "pattern_b": 3, "pattern_c": 2, "pattern_d": 3},
            "sense": ">=",
            "rhs": 250,
        },
        {
            "name": "xl_shirts_demand",
            "coefficients": {"pattern_a": 1, "pattern_b": 2, "pattern_c": 1, "pattern_d": 1},
            "sense": ">=",
            "rhs": 150,
        },
    ],
})
result = response.json()

print(f"Minimum rolls needed: {result['objective_value']:.0f}")
for var in result["variables"]:
    if var["value"] > 0:
        print(f"  Use {var['name']} {var['value']:.0f} times")

Templates

Bin Packing Optimizer

Apply cutting stock optimization to minimize fabric waste across patterns.

Production Planning Optimizer

Schedule garment production runs across sewing lines and shifts.

Next Steps