CHIATECH JOURNAL · Registered Version of Record

Optimizing Primary-School Uniform Mass Production Through Computer-Aided Basic-Block Development: A Reproducible Parametric Grading and Marker-Planning Experiment

1. Lydia Kachollom Akila
2. Godiya Chindang Mwanle
3. Mariya Mohammed Usman

Abstract

Background: Primary-school uniform production depends on repeatable sizing, accurate blocks and economical markers. Yet many small and medium clothing operations still redraft patterns by size and plan cutting layouts sequentially. Purpose: This study developed and evaluated a software-neutral, computer-aided workflow for translating a local three-size body chart into parametric school-shirt and trouser cutting envelopes and mixed-size marker plans. Methods: The design experiment used published aggregate measurements for 367 children aged 6-12 years in Jos, Nigeria. Three base profiles - JOS-115, JOS-130 and JOS-145 - supplied stature, chest, waist and hip inputs. Transparent drafting rules produced 15 cutting envelopes per uniform set. A deterministic best-fit-decreasing shelf algorithm was compared with a size-batched next-fit-row baseline under four production mixes and usable fabric widths of 140, 147 and 150 cm, yielding 12 scenarios. Primary outcomes were marker length and percentage reduction; modelled planar occupancy and fabric area were secondary diagnostics. Results: Across the nine 30-set production scenarios, optimized marker length was 7.51-12.32% lower than the baseline (mean 9.59%). Mean modelled planar occupancy increased from 63.57% to 70.31%, a gain of 6.74 percentage points. At 147 cm width, marker-length reductions were 8.61%, 9.31% and 10.21% for balanced, younger-heavy and older-heavy size mixes, respectively. These corresponded to projected savings of 107.4-140.3 linear metres of 147 cm fabric per 1,000 uniform sets under the model assumptions. Conclusion: Parametric grading and mixed-size marker planning can convert a local body chart into a consistent, auditable pre-production system and materially reduce modelled fabric demand. The cutting envelopes are proof-of-concept geometry, not production patterns; physical toile fitting, fabric-specific constraints, shrinkage and factory validation remain mandatory before adoption.

Keywords: computer-aided design; school uniform; basic block; parametric grading; marker planning; fabric utilization; mass production; Jos; Nigeria

Licence: CC BY 4.0

Published by CHIA TECH SOLUTIONS AND RESOURCES LIMITED. ISSN assignment remains pending.