Cutting Order and Lay Plan Sheet Template
The cutting room turns a fabric roll into thousands of pieces, and a single wrong ply count or size ratio can only be fixed by cutting again. This template records the cutting order, the marker, the size ratio and each lay in one printable document.
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Cutting Order and Lay Plan Sheet Template
Cutting Order and Lay Plan
Company: Acme Apparel Ltd Cutting order: CUT-2026-0412 Date: 2026-10-20 Style: ST-2210 Men's Polo Buyer / PO: Buyer A / PO 88421
Fabric and Marker
Fabric: Cotton pique 220 gsm, navy Usable width: 150 cm Marker length: 6.85 m Marker efficiency: 84 % Plies per lay: 80 Lay method: Face up, one way
Size Ratio and Cut Quantity
| Size | Ratio in marker | Order qty | Planned lays | Cut qty | Excess % |
|---|---|---|---|---|---|
| S | |||||
| M | |||||
| L | |||||
| XL | |||||
| XXL |
Lay Record
| Lay no. | Roll no. | Shade band | Plies | Length used (m) | End loss (m) | Spreader |
|---|---|---|---|---|---|---|
| 1 | ||||||
| 2 | ||||||
| 3 | ||||||
| 4 |
Remarks
Relax fabric for 24 hours before spreading. Check shade bands by roll. Mark defects on the fabric edge.
Approvals
Cut quantity per size = ratio x number of lays x plies. Total fabric for a lay = marker length x plies plus end allowance per ply. Starting point for your own process; adapt to buyer and factory procedures.
Cutting consumption reports from your ERP
Optional: discuss reporting planned versus actual fabric consumption per cutting order.
Optional. The tool and every export work without this. No spam.
How to use it
Fill in the style, buyer order and fabric. Enter marker length, marker efficiency, ply count and lay method. Print or export the sheet, then complete the size ratio and the lay record by hand on the floor, or paste the values into your ERP. Each lay row records the roll, shade band, plies, length used and end loss.
- Fill the size ratio before spreading starts, not after cutting
- Record the shade band of every roll to avoid shade variation inside a bundle
- Sign the sheet at lay approval so the audit trail is complete
The arithmetic
Cut quantity for a size = ratio in marker x number of lays x plies per lay. For a marker with ratio 1:2:2:1 and 80 plies over 10 lays, the cut quantity of the ratio-2 size is 2 x 10 x 80 = 1600 pieces. Marker efficiency is fabric area of the pieces divided by the marker area, which sets the net consumption. End loss per ply adds to length used.
Reading the result
Compare cut quantity with the order quantity per size and the allowed extra cutting percentage in the buyer contract. Excess above the agreed extra is dead stock; shortage means re-cutting from a different roll, which risks shade mismatch. The total length used divided by the pieces cut gives actual consumption, which you should compare with the costing sheet.
Common mistakes
Frequent problems are spreading more plies than the cutter can cut cleanly, not recording end loss, and mixing rolls of different shades in one lay. Planning lays to the maximum ply height without checking the order size ratio leaves odd quantities at the end. Review the sheet at each lay and keep it with the cutting bundles for traceability.
Frequently Asked Questions
What is a lay plan?
A lay plan states how fabric will be spread and cut for an order: the marker, the number of plies, the number of lays, the size ratio and the roll sequence. It converts the order quantity into cutting-room instructions.
How do I decide the number of plies?
Plies depend on the cutter blade height, the fabric type and the order quantity per size. Heavier fabrics allow fewer plies. Divide the largest size requirement by the ratio to see how many plies in total you need.
What is marker efficiency?
It is the percentage of the marker area covered by pattern pieces. Higher efficiency means less fabric waste. It depends on the style, grain rules and fabric pattern, and should be reviewed against the costing assumption.
Can I use the sheet for knit fabrics?
Yes. For knits, add relaxation time, tube or open-width details and any spirality checks in the remarks. The ratio, ply and lay record fields work the same way for knit and woven fabrics.
If cutting orders and markers are kept in an ERP or a PLM, we can set up a read-only assistant that compares planned and actual fabric consumption per cutting order and highlights excess cut.
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