An approach to reduce waste in mass production by developing minimal waste graded blocks within a multiple-size lay plan

Abstract

One of the fundamental issues of adopting zero waste mass production (ZWMP) is grading. This project proposes that minimal waste (MW) blocks in multiple-size lay plans could be a solution to help mass production apply zero waste pattern cutting (ZWPC). From my contrasting experiences as a designer working in a factory and an office, I found that communication between pattern cutters and designers are limited, which makes ZWPC hard to achieve in this dynamic. ZWPC needs to adapt to the reality of the pattern cutters-designers’ work dynamic instead of suggesting that they need to work together to make ZWMP achievable. Making MW garments instead of ZW is a compromise that helps reduce waste in mass production within the conventional design and production process while trying to avoid compromising design aesthetics, fitting, and time during the process. Making a more realistic approach to adopt in mass production. When designing a ZW garment, the designer should have a clear plan to consider the technical aspects besides the final appearance (Saeidi and Wimberley, 2018). Using graded MW blocks will help the designer focus more on the design instead of grading or fitting issues. This will also demand less collaboration between the pattern cutter and the designer. Most importantly, it does not rely on experiments, which is more suitable for the factory environment. However, the designer’s basic knowledge of ZWPC methods is still needed to alter the MW blocks. This project is supported by a series of designs developed using the MW blocks for a dress, bodice with sleeves, and trousers to justify the approach. Terms bolded throughout the text have been expanded upon in Appendix 8.1 for a greater understanding of the research perspective.