Mathematical Model to Upcycle End-of-Roll Leftover Fabrics in Apparel Manufacturing

This study addresses the problem of end-of-roll leftover fabrics originating after the production of baby/child apparel. The ineffective management of these leftovers results in excess inventory, occupies storage space, and imposes economic and environmental loads. To address this challenge, a novel mathematical modeling approach is proposed. The model maximizes the upcycling of leftovers by incorporating these into the manufacturing of garments while adhering to marketing, production, and ordering constraints. This model also introduces the feasibility of ordering new fabrics with a penalty, as defined by the decision makers, to increase utilization. The model was tested using actual end-of-roll leftover data. The upcycling utilization of leftovers was calculated to be between 57% and 87%. Notably, at an upcycling rate of 58%, 96% of the utilized fabrics were sourced from leftovers. The case study results validate the model efficacy and provide insights into leftover-fabric management.