Blended Prototyping: a conceptual framework towards

lean sustainable supply chainCase Study in Fashion Industry

Dr. Maged Youssef, PhD

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Questions to Answer?

• What is the traditional prototyping process in apparel export-import context?

• How could we improve the prototyping process by integrating 3D visual technology (blended process)?

• What is the impact of using this new concept on the prototyping process?

Contents:

• Supply Chain Management for Garment Production

• 3D design technology and Virtual prototyping

• Case Study : Virtual Lean prototyping

Supply Chain Management for

Garment Production

The supply chain for garment production

Rawmaterials Producerdyeing/

finishing

Weaving/

knittingSpinning

1 2 3 4 5 6

Brand/

Customer

The supply chain for garment production

Rawmaterials Producerdyeing/

finishing

Weaving/

knittingSpinning

1 2 3 4 5 6

Brand/

Customer

Fabric

Supply

1

Accessory

Supply

2 4

In-house

Production

3

Sub-

contractors

The supplier’s immediate

supply chain

Problems can’t be solved only between supplier and customer

Rawmaterials Producerdyeing/

finishing

Weaving/

knittingSpinning

1 2 3 4 5 6

Brand/

Customer

Fabric

Supply

1

Accessory

Supply

2 4

In-house

Production

3

Sub-

contractors

The supplier’s immediate

supply chain

PRICE

SPEED

ON-TIME

DELIVERY

QUALITY

SOCIAL

Rawmaterials Producerdyeing/

finishing

Weaving/

knittingSpinning

1 2 3 4 5 6

Brand/

Customer

Fabric

Supply

1

Accessory

Supply

2 4

In-house

Production

3

Sub-

contractors

The supplier’s immediate

supply chain

Problems can’t be solved only between supplier and customer

PRICE

SPEED

ON-TIME

DELIVERY

QUALITY

SOCIAL

Problems must be solved throughout the chain

Rawmaterials Producerdyeing/

finishing

Weaving/

knittingSpinning

1 2 3 4 5 6

Brand/

Customer

Fabric

Supply

1

Accessory

Supply

2 4

In-house

Production

3

Sub-

contractors

The supplier’s immediate

supply chain

PRICE

SPEED

ON-TIME

DELIVERY

QUALITY

SOCIAL

How does SCM work?

Rawmaterials Producerdyeing/

finishing

Weaving/

knittingSpinning

1 2 3 4 5 6

Brand/

Customer

Fabric

Supply

1

Accessory

Supply

2 4

In-house

Production

3

Sub-

contractors

PHASE 1: Prototyping

Producer

5

3

Sub-

contractorsAccessory

Supply

2

Fabric

Supply

1

How does SCM work?

Rawmaterials Producerdyeing/

finishing

Weaving/

knittingSpinning

1 2 3 4 5 6

Brand/

Customer

Fabric

Supply

1

Accessory

Supply

2 4

In-house

Production

3

Sub-

contractors

Producer

5

4

In-house

Production

PHASE 2: prototyping optimization

3

Sub-

contractorsAccessory

Supply

2

Fabric

Supply

1

How does SCM work?

Rawmaterials Producerdyeing/

finishing

Weaving/

knittingSpinning

1 2 3 4 5 6

Brand/

Customer

Fabric

Supply

1

Accessory

Supply

2 4

In-house

Production

3

Sub-

contractors

PHASE 3: Brand requirements

Producer

5

4

In-house

Production

Brand/

Customer

Folie 15

2D-operation – Bodywear

Design specs

Body measurements

Anthropometric knowledge to derive rules of proportion

Development of construction classifications (cuts)

Folie 16

3D-Body-Scanner

International available systems

3D body scanners allow the collection of anthropometric data at a very high level of accuracy without touching the human body.

3D-Body-Scanner von

Vitronic

HUMAN BODY

Folie 19

Creating the peripheral lines on the figurine

Length of the perimeter

Value of the hip girthin measurement table

Skalierungs-faktor

Anchor point

rot

blau

scaled circumferential line

All measurements shall be entered in MS Excel tables and linked to scale the geometry model with the CAD system.

Cutting level of the terso

Parametric models (circumference scaling)

Folie 21

3D-Construction Method

It does not require mathematical formulation of the relationship between the body and the two-dimensional pattern pieces and is based on an intuitive way of working

Model Design

Product development of Bodywear

Automatic generation of 3D-surface into 2D-cutting patterns (Maged Kamal,2013).

scaling Surface generation Model design 3D generation 2D pattern

Fabric Assurance by Simple Testing (FAST)

• Tensile properties

• Bending properties

• Compression

• Dimensional stability

FAST 1 Compression

Meter

FAST 2 Bending Meter

FAST 3 Extension Meter

FAST 4 Dimensional

Stability

Folie 24

Processing (material based)

Implementation of Stress-Strain curves in simulation software

Folie 25

Visualisation

Fit simulation

Background information on the companies in the exploratory study

A B C D E

Nature of

business

manufacturer manufacturer manufacturer manufacturer manufacturer

Product

sector

knitwear knitwear knitwear knitwear variety

Turnover

(USD)

30 million 10 million 7 million 6 million 20 million

Geographic

market

served

North

America and

Europe

North

America and

Europe

Europe North

America

USA,Europe

Number of

employees

1300 560 450 380 1000

The traditional sampling process and its potential to be made virtual

conceptual Model for blended sampling process (developed by author)

Virtual samples

Physical samplesSM: Size measurements

MP: Material Properties

3

4

12

4

4

2

8

2

2

1

-

-

4

4

-

4

2

2

the average number of physical samples has to be reduced by 59 %

Sample process types NO New

Total Number of Samples 41 17

Expected benefits

• 24 samples x $20 = $ 480/ order

• 480X 200 order/year = $96000/year (potential Savings

• Pay back Period= 150000/96000= 1.56 Years

• Prototyping lead time reduced by 50%

• Enhancing customer satisfaction, creativity and improve communications

Conclusion

Lean blended prototyping framework is a new concept that could

contribute effectively towards lean sustainable supply chain

management.

References• Maged Kamal (2014/1), Producing of customized comfortable sportswear

using three dimensional (3D) technology, International Design Journal-volume 4 issue 2

• Maged. Kamal (2014 /2), Effect of adoption the Visual Production Planning and Control System (VPPCS) in apparel manufacturing companies , International Design Journal- volume 4 issue 3

• McNally, R. C., Akdeniz, M. B. and Calantone, R. J. (2011). New Product Development Process and New Profitability: Exploring the Mediating Role of Speed to Market and Product Quality. Journal of Product Innovation Management. Vol. 28 No.1, pp. 63-67

• Rudolf, A.; Jevšnik, S. & Stjepanovič, Z. (2012). Influence of Knitted Fabric’s Stretch on Virtual Prototyping of the Underwear, Proceedings of 14th Romanian Textiles and Leather Conference, 46th International Federation of Knitting Technologists Congress, Dodu A. (Ed.), Blaga M. (Ed.), pp.946-953, Sinaia, Romania, 6-8 September.

Thank you for your kind attention