Cutting Plan Mathematics: Worked Examples

A cut plan turns an order's size-and-colour breakdown into a set of cuts (markers × plies) that produce exactly the right quantities within the machine's ply limit. The core is one formula; the skill is splitting the order cleanly. Here is the formula and three worked examples.

The core formula

Cuts required = Total quantity ÷ (Max ply × Garments per marker)

Round up to a whole number of cuts, then distribute quantities across cuts so each cut stays within the ply limit and the totals match the order.