Shoe Material Consumption Methods
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Sadikul IslamShoe Material Consumption Methods
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Sadikul IslamCommon questions
Powered by AISATRASumm, developed in the early 1980s, differs from SLM primarily in its continued development and adaptation to industry standards for material allowance calculation. While both systems aim for accurate allowance calculation, SATRASumm has taken over as the industry standard, suggesting improvements or updates over the original SLM introduced in the 1950s. Where SLM focused on separating pattern assessment and leather assessment, SATRASumm likely refined these processes, incorporating more contemporary requirements in cost estimation .
The evolution from methods such as marking-up to scientific ones like RSM and SLM indicates a shift towards increased precision and systematic approaches in consumption calculation. RSM, established in 1922, laid the groundwork for scientific calculation by introducing a systematic way of arriving at consumption allowances using net and gross areas accounting for waste. SLM, introduced in the 1950s, further refined scientific calculation by separating pattern and leather assessments, demonstrating an increased understanding for accurate material estimation. These changes reflect broader industrial trends towards efficiency, accuracy, and consistency in manufacturing.
The graphical method involves laying out patterns compactly on graph paper, calculating the rectangle that encloses them, and applying percentages based on experience. It's quick and provides a permanent record but can be subjective due to variations in original rectangle size, and may not reflect usual cutting practice. The RSM method is more scientific, introduced in 1922, measuring actual net area of each pattern item (scale area) and incorporating first wastage and interlocking waste. While RSM is more systematic, it requires detailed pattern analysis, making it potentially more accurate compared to the graphical method, which relies on prior cutting experience .
The marking-up method has several advantages, including allowing experienced cutters to factor in cutting principles and quality requirements, thereby potentially minimizing wastage. However, it has notable disadvantages, such as requiring a highly skilled and trustworthy cutter, being time-consuming, and potentially not reflecting actual cutting practices. It also lacks adjustment for leather grading or shoe size, which can result in inconsistent results. This method may not emulate actual cutting practice since cutters could prefer different cutting patterns than those assumed during the mark-up .
Accurate calculation of material consumption directly affects a shoe company's profitability by ensuring precise material requirement planning and cost control. Overestimating can lead to excessive inventory and wastage, while underestimating might result in production delays and inability to meet demand, both of which incur costs. By using accurate methods, the company can optimize material usage, reduce unnecessary expenses, and improve overall cost efficiency, thus enhancing profitability .
Maintaining consistency in material consumption calculation across styles and shoe sizes is important for ensuring reliable and comparative cost data, facilitating better inventory management and planning. Consistency allows for the standardization of material allowances, which is critical for cost estimation, pricing, and profitability analysis. Inconsistency can result in inaccurate predictions and financial forecasts, jeopardizing the efficiency and economic viability of production processes .
Applying a uniform percentage across different shoe styles and materials presents challenges because variations in material type, quality, and size influence material consumption. Uniform percentages may not accurately reflect the actual consumption needed for each specific style or material, potentially leading to underestimation or overestimation of material needs. This approach might ignore specific characteristics such as cuts, fits, and interlocking capabilities that differ significantly among materials, thereby affecting overall accuracy and economic efficiency .
Accurate calculation of upper material consumption is crucial in shoe production because the upper typically constitutes the largest cost in shoe material. It ensures accurate material requirement planning and product costing, which ultimately contributes to the profitability of the shoe company. Moreover, it facilitates setting up consumption allowances for product development and helps control material wastage during cutting, as inconsistency or inaccuracies can lead to significant discrepancies in costs and wastage .
In the graphical method, the percentages applied to calculate material consumption vary with material type and quality. These percentages are typically based on historical data reflecting average pattern area versus material area, and variations due to size and width fittings. Material differences mean that the same base area can yield different allowances, affecting the method’s accuracy and reliability if previous experience doesn’t account for new material types or qualities accurately .
'Clicker Allowance' determines the intensity of the upper material given to a clicker, the cutter, to make a pair of shoes. It serves as a benchmark for assessing the amount of leather saved, thereby enabling a results-based payment system. This allowance helps ensure consistency in material usage and cost management, serving as a standard against which actual cutting results can be measured to avoid excessive wastage .