TPO

Total Production Optimization (TPO) FabricOptimizer

for the Apparel & Footwear Industries

A fully integrated solution for dynamic marker making, roll-picking and cut-planning optimization

Solution Overview

TPO is NOT just about nesting

Plataines Total Production Optimization (TPO)

solution offers Apparel & Footwear manufacturers
an integrated solution for dynamic marker making,
roll-picking and cut-planning optimization.

TPO FabricOptimizer vs. Nesting Software:

Higher material utilization

Nesting
Software
Role in
organization

TPO drives significant cost savings and increased

productivity through process automation and
resource optimization.

Engineer-Level
Enterprise level solution
solution

Input

Parts &
Geometry

Parts & Geometry, Customer

Orders, Available Fabric
Rolls,
Machine capabilities &
availability

Output

Marker only

Optimized Production plan

Automation

Marker only

End-to-end process
automation

Just-in-time production and methodical remnant

utilization (short-end rolls)

Faster & more flexible time to market of
customizable products
Time & Labor savings and better machine utilization
Automating routine manual tasks and eliminating
associated human errors.

TPO FabricOptimizerTM

Optimization Marker only

Integrated Optimization
of multiple factors, while
balancing all elements at
once

Expected
value

Production Efficiency

Marker
efficiency

Bridging the worlds of ERP, CAD/CAM and shop-floor systems

TPO bridges the gap between the market and the production floor
Seamlessly integrates to the

ERP/MRP

manufacturers ERP/MRP and CAD

systems

Creates ready-to-cut production

plans

Customer orders
& Inventory

Matches the order due date, size and

specifications, actual material size,

stacking considerations and other
parameters, such as batch, shade and
special patterns

Integrated Solution

TPO
FabricOptimizer

Optimally selects the rolls to use,

generates the optimal marker for

each spread

CAD

TPO optimally decides

WHICH order to
produce, WHEN and
WITH WHAT roll(s)

Product
design
information

Marker & Roll Details

411 Waverley Oaks Rd, Suite 331, Waltham, MA, 02452 U.S. | Toll free: 1-866-500-5902 | info@plataine.com | www.plataine.com

Process Automation and Resource Optimization

Best of class, dynamic marker marking capabilities:
Leave your static markers behind with TPOs unique
dynamic marker making capabilities. TPO evaluates
millions of marker options in a limited time to identify
the optimal solution for any given customer requirement
and inventory levels.
Methodical use of remnant (short-end) rolls: TPO
automatically selects the optimal set of rolls from
inventory for the markers, and can split a single order
over multiple rolls, including roll remnants.
Cut Order Planning: TPO Identifies optimal mix of
Product/Styles/Sizes, based on the actual order mix and
rolls in stock to achieve optimized material utilization
and cut/spread plan.
Supports both single and multi-ply cutting: including
detailed spreading instructions such as roll id, spread

length, roll overlaps (splicing), roll width consideration,

etc.
Generate markers with any fabric type or pattern:
TPO fully supports all fabric patterns, including nesting
of Stripes & Plaids or patterns with flipping or rotating
constraints.
Mixes orders for optimized material usage: Combine
multiple orders and/or different products made of the
same fabric on a single roll.
-- Sectional Marker Making.
-- Combining Multiple Orders on the same roll,
considering stripe and other offsets.
-- Supports splice Spreading.
Inter-operable with leading CAD systems: TPO supports
multiple import and export formats, including: DXF, HPGL,
NC Cut, CRV, Gerber, Lectra (PLX/MDL) and many more.

Low
Ply
Cutting

Optimal
Stacking

Single
Ply
Cutting

Remnant
Utilization

High
Ply
Cutting

Cut-OrderPlanning

Increased Process Automation & Optimization through increased material utilization, more
flexibility, faster time to market, reduced overcuts, lower inventory costs and less mistakes
Size(s)

# of Plies

L2, M2

26 plies

S, M2

19 plies

L1

40 plies

135cm wide
x7 plies
141cm wide
x12 plies
146cm wide
x9 plies

Remnants of 3.1m + 7.1m

+

TPO automatically generates an optimal cut

plan, mixing products, styles and sizes based
on actual orders and fabric inventory
No static markers are made to fixed quantities
or arbitrary material sizes
Eliminate need to create and maintain marker
libraries
TPO automatically generates optimal markers
and spreading plans, based on optimal roll
selection and actual material width in stock
Markers not limited to standard (minimal)
material width, fully utilizing wider fabric in
stock
TPO methodically utilizes short rolls (remnants)
in stock by dynamically nesting over multiple
rolls (where possible), and keeps short rolls
inventory to a minimum
No static markers that are limited to single rolls
TPO Matches rolls by fabric style, shade, lot etc.

TPO FabricOptimizer is part of Plataines integrated Total Production Optimization (TPO) suite. Other TPO applications include:

TPO Production Scheduler & Shopfloor Terminals Automatically and optimally assigns work to the appropriate work
centers and machines, provides manufacturing information to station operators and collects progress reports in real time.

Management Dashboards and Reports Provides both floor-supervisors and executives with a wide range of production
metrics in real-time, including machine status, planned vs. actual progress, machine utilization and more.

ABOUT PLATAINE

Plataine is a leading provider of production optimization solutions for manufacturers of textile, metal, wood and compositematerial products. Plataines production optimization solutions enable manufacturers to be more competitive by increasing
material utilization, improving productivity, and shortening manufacturing cycles to ensure on-time delivery of products
to customers. Plataines customers include Bassett Furniture, Boeing, Century Furniture, Drexel Heritage, Ethan Allen,
Ford, General Motors, The Gap, Hagger, Interstate Foam & Supply, Gurit, Hexcel, Lazar Industries, Fruit of the Loom,
Vanity Fair, Nike, and Wrangler. For more information, please contact your local Plataine office or see www.plataine.com
2011 Plataine Ltd. | All Rights Reserved
411 Waverley Oaks Rd, Suite 331, Waltham, MA, 02452 U.S. | Toll free: 1-866-500-5902 | info@plataine.com | www.plataine.com