Cut Order Planner (lay plan from order quantities, size ratio and maximum plies)
Markers, lays and plies for a garment order, with the fabric each colour needs.
Try before you buy.
- Free preview: lays and plies for the order in full, with the first rows of each table (up to 3) and a watermarked chart; every other figure is hidden.
- Locked until you unlock it: download, copy and print.
- Unlock: Premium pass, ₹799 for 30 days or ₹249 for 1 week, a one-time payment unless you choose automatic renewal. Unlock: Premium pass, $19.99 for 30 days or $7.99 for 1 week, a one-time payment unless you choose automatic renewal.
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About the Cut Order Planner (lay plan from order quantities, size ratio and maximum plies)
Before a garment order is cut, the cutting master plans the markers — how many pieces of each size one ply holds, the size ratio — and the lays: how many plies of each colour are spread under each marker. Fewer markers save marker-making time, fewer lays save spreading and cutting time, and a close fit saves fabric and over-cut pieces.
Enter the pieces ordered by colour and size, the cutting allowance, the plies a lay your spreading and cutting allow, and the garments a marker can hold (or the table length with the marker length a garment of each size). The tool works out the pieces to cut, picks markers that cut the most of the order within the over-cut you allow — reusing a marker across colours when the size curve allows — splits each marker’s plies into lays within the lay height, and adds up the pieces cut and the fabric each colour takes.
Without a pass the plan is a free preview: the lays and plies for the order in full, with the first rows of each table and every other figure hidden. The full plan, the PDF, Excel and CSV files, copying and printing come with a Premium pass.
How to use it
- Name the style and the order, then enter the pieces ordered of each colour and size in the grid, or paste the order table from a spreadsheet.
- Optionally enter the marker length a garment of each size (metres, from a trial marker or the costing): it gives the fabric and keeps markers within the cutting table.
- Set the cutting allowance, the plies a lay at most, the garments a marker at most (or the table length), the end allowance a ply and the over-cut you accept a size.
- Read the plan under the form: the markers with their ratios, the lays with their plies, the pieces cut against the pieces needed, and the fabric by colour.
- Without a pass the plan stays a free preview; with a Premium pass, use Copy, PDF, Excel, Lays (CSV) or Print to hand it to the cutting room.
Examples
One colour: S 400, M 800, L 800, XL 400; no allowance; 100 plies a lay; 6 garments a marker
4 lays · 400 plies with one marker S1 M2 L2 XL1: 2,400 pieces, no over-cut
Every size is a multiple of the same 400 plies, so the ratio 1 : 2 : 2 : 1 cuts the order exactly in four lays of 100.
S 230, M 470, L 480, XL 220; 80 plies a lay; 6 garments a marker; 3 % over-cut allowed
Marker S1 M2 L2 XL1 over 226 plies in lays of 76, 75 and 75, then S1 M2 L3 over 10 plies; 16 pieces over-cut
XL gets 226 for 220 needed: 6 over, within 3 % of 220. Without that allowance the order would need more markers for its small remainders.
Common uses
- Cutting masters planning lays for a new order or a re-cut.
- Merchandisers and planners checking the fabric an order needs by colour.
- Small factories without CAD planning software that still want few markers and little over-cut.
- Training cutting-room staff on size ratios, lay heights and allowances.
How the plan is worked out
- Pieces to cut = pieces ordered × (1 + cutting allowance), rounded up for each colour and size.
- A marker holds at most the garments you allow, and with marker lengths a garment, a marker length (the sum of ratio × length) within the cutting table.
- Pieces cut of a size = the marker’s ratio for that size × the plies cut with it.
- A marker’s plies are split into as few lays as the plies a lay allow, shared out evenly.
- Fabric for a lay = plies × (marker length + the end allowance a ply).
The search starts with the largest colour. At each step it tries ply counts worked out from what is still needed and picks the marker and plies that cut the most without cutting any size beyond the over-cut you allow; a marker already made for another colour wins when it cuts nearly as much, because one marker fewer is worth a little more spreading. What is left at the end goes into the marker with the least over-cut.
Getting a good plan
- Enter the lay height for the fabric you are cutting: heavy fabrics take fewer plies than light ones.
- Garments a marker is limited by the table and by what your marker maker can fit; with marker lengths a garment the tool keeps each marker within the table.
- A small over-cut allowance can save a whole marker for a few remaining pieces; 0 % cuts only what is needed, except for the last marker of each colour.
- Plans are worked out per colour, so shades are never mixed in one lay; colours with the same size curve share markers.
Limitations
- The plan is a good, transparent plan, not a proven optimum: check it against your marker maker’s output before cutting.
- Marker lengths a garment are an input: the tool does not make markers, nest patterns or check fabric width.
- Colours are planned in lays of their own; spreading several colours on one marker together is left to the cutting room.
- Shrinkage, shade bands and fabric faults are not counted: add them in the cutting allowance.
- One plan holds up to 5,000,000 pieces to cut and 3,000 lays; plan a larger order in parts, some colours or one delivery at a time.
- Your order is kept in this browser on this device only; save it as a file to move it to another device.
Privacy
On this device; its files download once
Everything happens in your browser. Your order is not uploaded; it is kept in this browser’s local storage until you clear it, and an order you save as a file is yours.
Frequently asked questions
What do I get without a pass?
Without a pass, Cut Order Planner (lay plan from order quantities, size ratio and maximum plies) shows lays and plies for the order in full, with the first rows of each table (up to 3) and a watermarked chart; every other figure is hidden. Until you unlock it, the result can’t be downloaded, copied or printed. A Premium or Ultimate pass, a one-time payment unless you choose automatic renewal, unlocks the full result. The pricing page lists the passes and their prices.
What is a size ratio?
How many pieces of each size one ply of a marker holds. S1 M2 L2 XL1 means each ply gives one S, two M, two L and one XL: six garments a ply. With 100 plies the lay gives 100 S, 200 M, 200 L and 100 XL.
Why does the plan cut a few more pieces than needed?
Because pieces come in whole plies of whole ratios. The over-cut you allow lets a marker cover a size with a few extra pieces instead of needing another marker for a small remainder; the last marker of a colour covers what is left with the least over-cut it can.
Can colours share a marker?
Yes. When a second colour has the same size curve, the marker made for the first is reused with that colour’s own plies, so the plan needs fewer markers. Each colour still has lays of its own.
How is the fabric worked out?
For each lay, plies × (marker length + end allowance), where the marker length is the sum of the ratio × the marker length a garment of each size. Enter those lengths in the last row of the grid to see it.
What do I need a pass for?
For the full plan and its files, a Premium pass. Without one, the free preview shows the lays and plies for the order in full, with the first rows of each table and every other figure hidden; the PDF, Excel and CSV files, copying and printing are locked. Saving your order as a file of your own entries works without a pass.