Short Answer
Cut plan is the plan for how many pieces to cut, in which sizes, colors, and fabric lots, and in what sequence. Sewing plan is the plan for how many pieces to sew on which line, in what sequence, and by what date. Cut plan is upstream of sewing plan.
What is a Cut Plan
A cut plan breaks the order into cutting batches. It specifies size ratio, color, fabric lot, ply height, cutting date, and cutting table. It is driven by fabric availability and sewing line requirements.
What is a Sewing Plan
A sewing plan assigns cut pieces to sewing lines with dates and quantities. It considers line capacity, SMV, style complexity, and skill availability. It is driven by delivery dates and line capability.
Practical Example 1 — Cut Plan
Order of 30,000 pieces in sizes S, M, L, XL (ratios 2, 4, 3, 1). Fabric is 3 shades. Cut plan splits into 15 cuts of 2000 pieces each. Each cut is one shade and one size combination. Cutting runs daily for 15 days.
Practical Example 2 — Sewing Plan
Two lines are assigned to this order. Line 1 takes sizes S and M, Line 2 takes L and XL. Each line sews 1000 pieces per day for 15 days. Sewing starts on day 3 after the first cut is done.
Practical Example 3 — Sequencing
Cut plan sequences cuts by shade, then by size, then by line requirement. Sewing plan sequences by delivery date, then by line availability, then by style difficulty.
Practical Example 4 — Constraint
If fabric for shade 2 is delayed by 1 week, cut plan shifts shade 2 to week 2. Sewing plan adjusts line allocation to work on shade 1 first and avoid idle lines.
Common Mistakes
Cutting without a plan based only on gut feeling. Sewing plan ignoring cut plan. Not adjusting plans when fabric is delayed. Making cut plan without understanding line capacity. Making sewing plan without understanding fabric availability.
How They Work Together
Cut plan creates the pieces. Sewing plan consumes them. Good factories integrate the two plans in a single Excel or ERP system. The cut plan sets the pace for fabric use; the sewing plan sets the pace for delivery.
When to Use Each
Cut plan is used weekly, updated daily based on fabric in-house. Sewing plan is used weekly, updated daily based on cut availability and line status. Both plans are reviewed in the weekly planning meeting.