What material utilisation tells you
Area utilisation is the share of pattern-piece area within the material area being considered. Pieces totalling 8 m² on a 10 m² material area give 80% geometric utilisation. This alone does not capture all costs or losses.
Choose the right reference area
Record whether you use the full roll width or only the usable width. Selvedges, end allowances, defects and remnants can change the calculation. Only compare results using the same definition.
Fix the constraints before comparing
Both methods must use the same piece list, quantities and constraints. An apparently better solution can be unusable if it rotates pieces against the pile or violates required spacing.
- Keep material width and edge allowances equal
- Use identical rotation, mirroring and grain rules
- Compare quantities and complete product sets
- Record computation and manual working time separately
A percentage point is not a percentage saving
An increase from 75% to 80% is five percentage points of utilisation. For a fixed net piece area, material required falls by 6.25%: 1 − 0.75 / 0.80. The material calculator uses this relationship and exposes its assumptions.
Evaluate the result alongside production
Consider handling, bundling and remnant material too. A compact marker can create more work in the next production step. Evaluate the entire job and document what improvement was actually measured.