Official Factory User Manual

OptiFabric AI User Manual

English

Official operating guidance for Cutting Masters, Cutting Supervisors, Production Officers and Factory Managers.

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Cutting Master

Cutting Supervisor

Production Officer

Factory Manager

Important Engineering Rule

OptiFabric AI provides engineering support and recommendations. Physical pattern checking, trial cutting and authorised factory approval remain mandatory before bulk production.

Cutting Master

Primary Responsibility

Prepare accurate pattern information, trace pattern boundaries and review AI marker recommendations before cutting.

01

Pattern Photo Preparation

/optifabric/cutting-assistant/upload

Purpose

Prepare a clear pattern image that the application can use for engineering measurement.

Why Does AI Ask for This?

AI needs a clear top-down image and a known measurement reference to calculate the real pattern size.

Step-by-Step Operation
1

Place one pattern piece on a clean, flat and contrasting background.

2

Place a 12-inch ruler or 30-centimetre scale beside the pattern.

3

Keep the ruler and pattern on the same flat surface.

4

Take the photograph directly from above.

5

Ensure the entire pattern and ruler are visible.

6

Check that there is no shadow, fold or obstruction.

Expected Result

A complete and clearly visible pattern image suitable for calibration and tracing.

Common Mistakes
•

Taking the photograph from an angle.

•

Using a ruler that is partly hidden.

•

Including more than one overlapping pattern piece.

•

Using a background similar to the pattern colour.

•

Cutting off part of the pattern in the photograph.

Best Practices
•

Use strong, even lighting.

•

Use one photograph for each pattern piece.

•

Use a white background for dark patterns.

•

Check image sharpness before uploading.

02

Upload Pattern

/optifabric/cutting-assistant/upload

Purpose

Upload the prepared pattern image or document into the OptiFabric workflow.

Why Does AI Ask for This?

The uploaded file is the engineering source used for scale calibration, tracing and area calculation.

Step-by-Step Operation
1

Open the Upload Your Pattern screen.

2

Select the required fabric or pattern category when available.

3

Choose a PDF, JPG, JPEG or PNG file.

4

Review the AI photo-quality guidance.

5

Confirm that the correct file has been selected.

6

Continue to the tracing workflow.

Expected Result

The selected pattern is loaded and ready for engineering review.

Common Mistakes
•

Uploading the wrong pattern piece.

•

Uploading a blurred or compressed image.

•

Using an unsupported file format.

•

Continuing without checking the ruler.

Best Practices
•

Use clear file names such as Shirt-Front-Medium.

•

Keep the original image safely stored.

•

Confirm the style number and pattern-piece name.

03

Boundary Tracing and Calibration

/optifabric/cutting-assistant/pattern-analysis

Purpose

Mark the outer boundary of the pattern and convert image measurements into real engineering dimensions.

Why Does AI Ask for This?

AI needs boundary points to construct the pattern polygon and the ruler length to convert pixels into real measurements.

Step-by-Step Operation
1

Confirm that the pattern image is displayed correctly.

2

Set or verify the ruler calibration.

3

Click around the outer edge of the pattern.

4

Add extra points around curves and corners.

5

Avoid placing points inside the pattern.

6

Close the polygon by connecting the final point to the starting point.

7

Review the complete outline.

8

Reset and trace again when the outline is incorrect.

Expected Result

A closed engineering polygon representing the actual pattern boundary.

Common Mistakes
•

Using too few points around a curved edge.

•

Leaving the polygon open.

•

Tracing seam lines instead of the cutting edge.

•

Clicking outside the pattern.

•

Using an incorrect ruler calibration value.

Best Practices
•

Use more points for complex curves.

•

Zoom the browser when detailed tracing is required.

•

Trace the actual cutting boundary consistently.

•

Review the first and last point carefully.

04

Polygon and Area Review

/optifabric/cutting-assistant/marker-layout

Purpose

Review the constructed pattern polygon and calculated pattern area.

Why Does AI Ask for This?

Pattern area is required to estimate material use and evaluate marker efficiency.

Step-by-Step Operation
1

Review the displayed polygon shape.

2

Compare the polygon visually with the original pattern.

3

Check the calculated square-inch area.

4

Confirm that the ruler calibration is correct.

5

Return to tracing when the shape or area appears incorrect.

Expected Result

A validated pattern shape and reasonable engineering-area result.

Common Mistakes
•

Accepting an obviously distorted polygon.

•

Ignoring an unrealistic area value.

•

Using the result without comparing it with the paper pattern.

Best Practices
•

Compare key dimensions with the physical pattern.

•

Repeat tracing when the area differs significantly.

•

Record the pattern name and size with the result.

Cutting Supervisor

Primary Responsibility

Verify marker inputs, cutting-room conditions and practical execution requirements.

05

Fabric and Marker Information

/optifabric/cutting-assistant/marker-layout

Purpose

Enter the available fabric width and marker information for layout evaluation.

Why Does AI Ask for This?

AI must know the usable fabric width and marker length to calculate available marker area and utilisation.

Step-by-Step Operation
1

Confirm the actual usable fabric width.

2

Enter the marker length in the requested unit.

3

Select the correct fabric type when the option is available.

4

Confirm whether the fabric is solid, striped, checked or printed.

5

Review the displayed marker area.

6

Continue to AI nesting.

Expected Result

Correct marker dimensions ready for pattern-placement analysis.

Common Mistakes
•

Entering total fabric width instead of usable width.

•

Mixing inches and centimetres.

•

Ignoring selvage allowance.

•

Selecting solid fabric for a striped style.

Best Practices
•

Measure usable width from the actual roll.

•

Check shade and fabric-lot information.

•

Confirm marker direction and grain requirements.

•

Record any fabric restriction before nesting.

06

AI Marker Layout Review

/optifabric/cutting-assistant/marker-layout

Purpose

Review the proposed placement of pattern pieces inside the marker.

Why Does AI Ask for This?

AI evaluates the empty spaces between pieces to estimate marker utilisation and potential fabric saving.

Step-by-Step Operation
1

Review whether all required pattern pieces are displayed.

2

Check that pieces remain inside the marker boundary.

3

Verify the grain direction.

4

Check one-way, nap, stripe and print restrictions.

5

Review spaces between pattern pieces.

6

Compare the AI arrangement with the existing factory marker.

7

Reject any arrangement that cannot be cut safely.

Expected Result

A practical marker proposal ready for engineering and production review.

Common Mistakes
•

Accepting overlapping pieces.

•

Ignoring grain direction.

•

Rotating a one-way pattern incorrectly.

•

Ignoring knife clearance.

•

Using the demonstration layout as an automatic cutting instruction.

Best Practices
•

Verify every pattern piece before bulk cutting.

•

Maintain safe spacing for the selected cutting method.

•

Use trial cutting when the style is new.

•

Obtain Cutting Master approval.

07

Cutting Readiness Review

/optifabric/pilot-dashboard

Purpose

Confirm whether the AI result is practically ready for a controlled factory trial.

Why Does AI Ask for This?

A mathematically efficient marker may still require operational checking for fabric behaviour, machine capacity and operator safety.

Step-by-Step Operation
1

Review the pattern and marker summary.

2

Confirm the fabric type and usable width.

3

Check whether spreading restrictions are recorded.

4

Confirm the expected number of layers.

5

Review cutting-machine capacity.

6

Check the operator skill requirement.

7

Authorise only a controlled trial before bulk cutting.

Expected Result

A supervised trial-cutting decision with known risks and controls.

Common Mistakes
•

Starting bulk cutting without trial verification.

•

Ignoring fabric slippage.

•

Using excessive lay height.

•

Assigning an unsuitable machine or operator.

Best Practices
•

Use a small controlled trial lay.

•

Check top, middle and bottom plies.

•

Review cut accuracy before bulk approval.

•

Record any change made after the AI recommendation.

Production Officer

Primary Responsibility

Verify order, consumption and production-planning information before material commitments are made.

08

Fabric Consumption Review (Legacy Demo)

/optifabric/cutting-assistant/fabric-consumption

Purpose

Review estimated marker efficiency, fabric utilisation and consumption using the legacy Cutting Assistant demo calculation — this does not use a project's saved Marker Run or Fabric Profile. For real project consumption, use Marker-Based Fabric Consumption in the Project → Marker workflow.

Why Does AI Ask for This?

AI compares pattern area with marker area to estimate utilisation, wastage and consumption.

Step-by-Step Operation
1

Confirm the style and pattern-size information.

2

Confirm the order quantity and size ratio when available.

3

Review marker efficiency.

4

Review fabric utilisation and estimated wastage.

5

Check consumption per garment.

6

Check total estimated fabric requirement.

7

Compare the estimate with the factory plan.

Expected Result

A reviewed engineering estimate suitable for planning discussion.

Common Mistakes
•

Using sample quantity instead of order quantity.

•

Ignoring size ratio.

•

Comparing different fabric widths.

•

Treating estimated consumption as final booking consumption.

Best Practices
•

Compare AI estimates with approved CAD or historical data.

•

Add approved process allowances separately.

•

Record the fabric width used in each comparison.

•

Escalate large differences for engineering review.

09

Fabric Saving and ROI Review

/optifabric/pilot-dashboard

Purpose

Evaluate potential fabric saving and its commercial effect on the order.

Why Does AI Ask for This?

AI needs current consumption, improved consumption, order quantity and fabric price to estimate possible commercial savings.

Step-by-Step Operation
1

Verify the current factory-consumption baseline.

2

Review the AI-improved consumption estimate.

3

Confirm the order quantity.

4

Confirm the fabric purchase price and currency.

5

Review the estimated total saving.

6

Separate estimated saving from confirmed saving.

7

Submit the result for management review.

Expected Result

A transparent savings estimate supported by verified commercial inputs.

Common Mistakes
•

Using an outdated fabric price.

•

Using unverified factory consumption.

•

Presenting projected savings as already achieved.

•

Ignoring additional process losses.

Best Practices
•

Use the latest approved fabric price.

•

Clearly label all assumptions.

•

Verify savings through an actual production trial.

•

Report both percentage and financial value.

Factory Manager

Primary Responsibility

Approve pilots, evaluate commercial benefits and ensure controlled implementation.

10

Complete Pilot Result

/optifabric/pilot-dashboard

Purpose

Review the complete engineering and commercial outcome of the OptiFabric trial.

Why Does AI Ask for This?

Management needs a combined view of marker performance, consumption, saving potential and operational risk before approving expansion.

Step-by-Step Operation
1

Review the style and factory information.

2

Review the pattern and marker results.

3

Check marker efficiency and estimated wastage.

4

Review consumption and financial saving.

5

Confirm that trial cutting was completed.

6

Review any difference between AI estimate and actual result.

7

Approve, revise or reject the proposed implementation.

Expected Result

A management decision based on engineering evidence and verified trial results.

Common Mistakes
•

Approving expansion using demonstration data only.

•

Ignoring operational feedback from the cutting room.

•

Reviewing only financial saving and not quality risk.

•

Failing to assign responsibility for implementation.

Best Practices
•

Require one verified pilot before wider rollout.

•

Include Cutting, Production, Quality and Industrial Engineering.

•

Approve measurable targets.

•

Review actual savings after production completion.

11

Factory Pilot Approval

/optifabric/pilot-dashboard

Purpose

Control how OptiFabric AI is introduced into factory operations.

Why Does AI Ask for This?

Controlled implementation protects fabric, production quality, delivery performance and customer commitments.

Step-by-Step Operation
1

Select one suitable pilot style.

2

Assign a responsible Cutting Master.

3

Assign a Cutting Supervisor and Production Officer.

4

Record the existing marker and consumption baseline.

5

Run OptiFabric analysis.

6

Complete a controlled trial cut.

7

Measure the actual outcome.

8

Approve the next pilot only after documented review.

Expected Result

A controlled, measurable and commercially accountable factory pilot.

Common Mistakes
•

Selecting a highly complex style for the first pilot.

•

Failing to record the original baseline.

•

Changing multiple production conditions during comparison.

•

Rolling out before the pilot report is approved.

Best Practices
•

Begin with a simple solid-fabric style.

•

Use the same fabric width for comparison.

•

Keep signed pilot records.

•

Review quality, productivity and saving together.

Factory Pilot Checklist

Complete every item before approving the pilot result.

1

Approved pilot style selected

2

Pattern images prepared correctly

3

12-inch ruler or 30-centimetre scale visible

4

Pattern boundary checked by Cutting Master

5

Usable fabric width confirmed

6

Existing factory marker recorded

7

Current consumption baseline approved

8

AI marker result reviewed

9

Controlled trial cutting completed

10

Actual result compared with AI estimate

11

Factory Manager approval recorded

Expected Factory Outcome

The factory should complete the OptiFabric pilot with verified pattern information, a reviewed marker proposal, a controlled trial cut, measured consumption and a documented management decision.

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