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Cutting Room Management System Economics Essay

In today's highly competitive global market, manufacturers face constant pressure to reduce costs, offer better product selection, and deliver products faster. Like many home manufacturers competing in the current international industry, the apparel industry has been required to up grade its responsiveness to customer needs. As a result, smaller requests are put in a more dynamic fashion, requiring the efficient development of smaller lot sizes. Effective and inexpensive production thus is dependent upon the interaction of many system components, one of the most critical as an successful workflow control system.

The lowering room keeps documents and catalogs for the many cutting functions they perform. Generally the books and registers they maintain are require a whole lot of manual entries and the well-timed retrieval of previous records is issues as these documents are very huge.

The focus of the task is on the means employed by the clipping room manager to instruct, keep an eye on and control the processing of fabric lowering room and personnel. Documentation after and during cutting is designed to authorize the issuing of materials from store, control the growing, slicing and bundling activities, help the evaluation of deficits and quantify loss against costed beliefs.

Cutting room is constantly challenged to cut costs on material usage. A small % of fabric kept during slicing can reflect a significant savings in the financial documents of the company. The Marker making alternatives are being used constantly to reduce fabric utilization while making markers. Another area where cost trimming can be carried out is by making a powerful cut plan. A highly effective cut plan will make sure that apparel are slice within the restrictions of the accepted quantity (as 5% extra delivery is allowed by the buyer against ordered goods), the required quantities are minimize with minimum variety of cuts (saving labor & time).

In most outfits industries, size blend i. e. how many and which sizes should be blended, in a marker is truly a very complex set of permutation & mixture. The number of parameters & possible combinations in most cutting problems exceeds real human abilities.

This projects aspires to defining something for effective management of reducing room and at the same time hooking up it to fabric inventory so that tabs on the fabric in inventory can be produced as most of the days the roll smart information of the textile in inventory is not known and fabric issue is not made against a trimming instruction. More often than not the fabric delivered from textile store is more than real requirement of reducing instruction for a specific day so effective track of the consumption of cloth is not manufactured in case there is absolutely no provision of dividends of excessive from cutting room. So building of the machine for effective flow is a need.


To design something which manages the actions that happen in a slicing room. The system should stand for a model of trimming room and activities are noted in to the system.


The system is to be connected to the cloth inventory or database thereby keeping record of every spin which is given for trimming.

To generate spin allocation plan for the cutting plan to minimize remnants.

To issue cloth against a lowering instruction.

Proper Spin allocation & comparing the actual material requirement of a production order up against the roll in the inventory.

Effective management of end parts form of end pieces, minimizing it & also tracking end bits. Storing and keep record of the remnants made in the reducing room following the spreading and making them designed for further use.

Generating of effective reports from the trimming room.


Cut your losses: functional tips to boost fabric produce in the trimming room.

Fabric makes up about 25-40 % of the price tag on making a garment, so controlling or negotiating cloth consumption has a substantial impact on the bottom line. In this article Robert Broadhead addresses the procedure of estimating fabric yields, the issues involved in just offshore contracting, and the way to be as accurate as it can be in predicting/negotiating cloth costs.

Fabric accounts for 25-40 % of the price of manufacturing a garment, so accuracy in this area is critical. It's been said a great deal over the years, but is worth repeating here: no other solitary refinement in production can provide large cost savings as easily as fabric control.

Controlling or negotiating cloth costs is becoming more complicated as overseas developing and cut-make-trim (CMT)/package programs have become. Before work gone offshore, in-house textile yield estimates and final development consumption mirrored the work of the reducing division (either the manufacturer's or an area contractor's) and was easily known and checked.

However, it is amazing that lots of businesses do not trail the variance between your actual cost of cloth at the end of creation and the estimated cost of textile on the charge of materials. This may significantly impact the bottom line.

To have a really effective material utilization, one need to check out all the factors that can donate to fabric deficits in cutting room. It might be impossible to remove all deficits in the cutting room, but incremental improvements in material utilization could significantly increase the important thing.

Width Utilization - careful dimension of the actual cloth received at a stock typically will show that more than 50% reaches least in. to 1 1 inch wider than the minimum purchased width. This unnecessary fabric width more often than not goes into the trash - yet it is functional and, if used properly, can cut costs. It requires the following actions:

Measure the width of & sort fabric when it's received. .

Plan markers by textile width.

Issue cutting orders by fabric width.

Marker & Marker copies - while copying the marker, whatever the process used, duration and/or width development or shrinkage may appear. Marker expansion can become more than 2% in acute cases, but can be reduced to less than % with proper machine modification. Following points should be taken health care of for correct marker & marker copies:

In case of computer plotted original manufacturers, keep the marker paper & the plotting of the marker in the same environment where the cloth will be trim.

Maintain the marker, storyline it at least once weekly, & strategy it accurately to do the mandatory adjustments.

While using the ammonia or alcohol method, permit the marker copy to air dried up, laid even for 2-3 hrs, before using I to tag the stand.

Spread planning - It is an examination of the rolls of fabric available to be multiply on existing sectional markers. The result is an idea of just how many pairs/plies from each roll should be located on each marker to reduce remnants. The requirements of this kind of system to work properly are:

Three or even more marker plus remnant marker can be used on each lowering order.

The markers must be different in measures.

Fabric flaw cutouts will demand recalculation of the rest of the fabric roll& a ensuing change in the growing chart.

The remnant marker is recently contained in the chart computations. It only is utilized for remnants left over from the key sections.

Table Marking - More cloth is thrown away in marking the stand than in any other facet of the growing process. Tables constantly are being designated for distributing where unnecessary spaces are allowed between markers, start/finish brand are purposely relocated outward and splice marks are elongated. It really is strongly urged that markers be prepared off-line by taping the individual marker sections jointly line-on-line with vast adhesive tape.

End Little bit Monitoring

An end little bit is a bit of towel that is longer than the distance required to place up one

complete size. End items of course comes into play all different measures, and unless you

'splice' there will be pieces of cloth that happen to be shorter than the space of the place being

layed, these bits should be cared for with great respect. They should be assessed, have a

sticky label attached with the length onto it, and then folded and put into hemorrhoids of similar

length to be used on smaller markers later. There is absolutely no point in keeping fabric for panel

replacement unless there are important reasons to do so, so one must produce garments

from all of the available cloth. The 'off cuts' (portions too small to produce a garment) will

be used to displace smaller elements of the garments that need replacement. The logic behind

this is that if a sizable panel in a garment is replced then every one of the income on that garment is lost.

Cut order planning - The dot com way stitchworld

It is interesting to notice that 'size combine' (how many & what size in mixed) in a marker is a brain boggling permutation & computation but actually made the decision by the CAD operator or "clipping professional" hypothetically rather than through any clinical process.

Generally the 'size mixture' & marker combinations (how many different kinds of markers are necessary for a given order variety) are generated predicated on factors like size & color ratio. There are a few infrastructural constraints like lay height, lay duration, & training the most ideal cut plan

There a wide range of optimal Chop Plan alternatives, induced by interplay of many dimensions. The various, but often conflicting, sizes are:

Less Textile - Maximizing the extreme size-mixing. That is emphasized upon when the order amount is high & the cloth is also expensive.

Less Labor & Time - Minimizing the no. of lays, leading to saving in dispersing cost.

Fewer Markers - Minimizing particular proportion, i. e. minimizing the no. of markers to prepare yourself. That is especially useful when one need to commit constant no. of sewing machines & workmen for order completion.

More Balanced Production - Minimizing deviation in level height across lays. This must be done when the order variety is low & the time & cost involved with marker making process is more compared to spreading & slicing.

More Balanced Packing - Simultaneous creation of garments of most sizes. Sometimes of urgency, interim plenty can be delivered to the customer without longing till the complete order complete.

Heuristics Algorithm

The term heuristic is used for algorithms which find alternatives among all possible ones, however they do not assure that the best will be found, therefore they may be considered as about and not exact algorithms. These algorithms,

usually find a remedy near to the best one and they find it fast and easily. Sometimes these algorithms can be accurate, that is they actually find the best solution, but the algorithm is still called heuristic until this best answer is proven to be the best. The method used from a heuristic algorithm is one of the known methods, such as greediness, but in order to be easy and fast the algorithm ignores or even suppresses some of the problem's needs. ( http://students. ceid. upatras)

Alternative formulations for design problems in garment industry

Before cutting, several levels of cloth are placed on a lowering table and many web templates, indicating how to lower all materials for a particular size, are set together with the stack. The condition involves finding good combinations of templates and the associated height of the stack of towel to satisfy demand while minimizing total excess development. considering high fashion clothing which is made by professional designers in small volumes. It is sold only in exclusive retailers. Typically, extremely expensive fabric are used. The high cost together with the limited demand make it advantageous to produce with minimal excess production, which is thought as the number of pieces which are produced above demand. Before production, demand data is accumulated both from placed purchases and forecasts. A demand establish for a specific little bit of clothing is composed of the demands for all those the different sizes. The towel is spread out in several layers on a clipping table. The number of layers of material is limited by the length of the knives and the width of the towel. For every size a stencil or template is made where all the several parts of the article are put in the most monetary way, in a way that they can be cut with reduced lack of exclusive fabric An excellent overview of solution techniques forgenerating good stencils are available in Dowsland and Dowsland (1995). An application of the garments trim location problem is described by Grinde and Daniels (1999). After the spreading, the decided on stencils are fixed on top The amount of stencils which is often lower in the same operation is bound by the length of the trimming stand. Since all the stencils have about the same period, the maximal volume of stencils up for grabs is independent of the combo of the stencils used. A possible combo of stencils is called a cutting routine. It really is quite possible that such a pattern contains several times the same stencil. After the cloth is propagate on the table and the stencils are set at the top, the cutting procedure can start. For these high fashion and incredibly expensive garments, dispersing of the fabric, correcting of the stencils and lowering are frustrating and costly procedures. Consequently you want to keep them at the very least. The problem is currently to find chopping habits and associated stack levels which minimize total excess production for a given demand.

The original design problem is very similar to the fixed demand lowering stock problem (FCCSP). Haessler (1975) and Farley and Richardson (1984) suggested heuristics for fixing FCCSP. However, the second area of the objectivefunction differs. Inside the FCCSP, the price of trim damage is reduced, whereas we reduce the price of overproduction. We need to stress that for our low-demand, high fashion clothing the expense of being near maximum, i. e. too much overproduction, can be very high, whereas for the popular clothing industry this isn't so much a difficulty. This cost concern, together with the fact that we are dealing with real life problems, justifies our seek out better optimal solutions. Farley (1988) described a planning model for a slicing stock problem in the clothing industry. He argues that this problem varies from the original clipping stock problem as a result of unique characteristics of the development process like the laying, stacking, trimming and sewing functions. Farley also makes an explicit difference between high-turnover garment, that overproduction and stock is allowable, and high fashion clothing, that stock and overproduction should be kept at the very least. He pointed out that the planning model he referred to is effective for high turnover garment, however, not for the made-to-order apparel because too much oversupply is produced. The model proposed here's explicitly focused on the high fashion clothing with little demand. Farley's model maximizes the full total contribution margin and considers demand and capacity constraints. It can be used as a planning tool but it cannot be used for resolving our arranging problem. A problem closely related to the is the lower order planning (COP) for outfits manufacturing, described by Jacobs-Blecha et al. (1998). The condition consists of finding how to spread the fabric, identifying how many levels to utilize and assigning various sizes to parts of the pass on. The main assumptions, however, won't be the same as those here and hence a direct contrast is extremely hard. COP permits example different stack levels on one lowering table. The creators adopt a minimal cost procedure. They consider the genuine fabric cost, growing cost, reducing cost and the marker making cost. The following constraints are taken into account: demand, a limit up for grabs span and an higher bound on the ply elevation. Since it is very hard to resolve their model optimally, they resort to heuristics. Their test data contain 20 orders, with 1-6 sizes per order and derive from true to life problems. They conclude the particular one of these heuristics is really as good as or better than the commercial deals. Elomri et al. (1994) also consider a lowering problem in the clothing industry. Their problem is composed in choosing trimming patterns and associated levels from a small collection of available patterns. The objective is to reduce total operating costs while satisfying demand. A linear approximation of the price function can be used. The main costs in the objective are the charges for cutting and textile.

Documentation and control of fabric usage.

The lowering room retains documents and literature for the various cutting businesses they perform. Usually the catalogs and registers they maintain are require a whole lot of manual entries and the timely retrieval of previous records is an issue as these documents are very vast.

The focus on the means employed by the reducing room manager to instruct, keep an eye on and control the handling of fabric lowering room and personnel. Documentation during and after cutting is designed to authorize the issuing of materials from store, control the growing, cutting and bundling activities, assist in the evaluation of loss and quantify losses against costed prices.

The large agreements are separate into small but financial batch sizes that are suitable for the handling in trimming rooms. The details of these individual batches are came into on a trimming instruction, which authorizes the issue of fabric and essential information for the growing and cutting. While the cutting instruction accompanies the material during its passing through the clipping room, the situation is checked by joining data on the reducing instructions record.

Management must control both the output of the reducing room, to achieve production targets, as well as the various functions to ensure that materials are efficiently used. The cloth reconciliation record offers a comparability of the genuine consumption and costed consumption and studies variances. This forms link between your cutting room activities and financial control projections as materials compromise roughly 40% of the creation costs, should be thought to be quite crucial.

Cutting Instruction is the key documentary outcome of cut order planning process. As the very least requirement of chopping instruction it will have the following information

1. the fabric to be refined.

2. the marker to be utilized.

3. the amount of plies authorized

Fabric utilization control

The substance of fabric reconciliation is that for each place a comparison is made between costed and real consumption of fabric, and the variance is reported. This report Performs an important role within management as it ties along what management organized to do with what they have achieved. Fabric reconciliation takes place after the fabric has been minimize.

Documentation & management functions.

Managers need to use documents but documents are no replacement for management. A director who enters data on documents is not carrying it out of a supervisor but is better referred to as a clerk. Documents are useful only once they allow managers make up to date decisions which change what sort of activities are carried out.

Cutting problems are NP-hard Thus, only small size problems can be solved optimally.

These problems are fixed using either integer linear encoding or dynamic

programming, or branch-and-bound, depending on the type of problem. But most of the cutting problems use heuristic algorithms.

Although any given solution to such an issue can be verified quickly, there is no known reliable way to locate a solution in the first place; indeed, the most notable characteristic of NP-complete problems is the fact no fast method for them is well known. That is, the time required to solve the situation using any currently known algorithm increases rapidly as the size of the problem develops. As a result, the time necessary to solve even reasonably large versions of many of these problems easily grows to into the billions or trillions of years, using any amount of processing power on the market. As a result, determining if you'll be able to solve these problems quickly is one of the principal unsolved problems in computer technology today.

Because (COP) is NP-complete, productive algorithms for realistically size problems will automatically be heuristic in nature. This insight leads to the necessity for analyzing (COP) for characteristics that may be exploited for development of heuristic methods. Jacobs-Blecha et al. (1998) identifies the heuristics developed for (COP), the reasoning behind these kinds of algorithm, and justification for the evaluation techniques.

Heuristic development is dependant on the examination of typical industry conditions that COP cost is dominated by total fabric length. It talks about the experimental design that we used to determine this attribute of the cost function. It ought to be noted that in some cases the price factors that are consider in the model developed may have a significant role in the expense of slash order planning. For example, spreading costs may be very high due to negotiated labor rates; slicing costs may be motivated up by manual or equipment variables; or a big data platform of historical markers might not exactly are present, greatly increasing the expense of that process. However, they assumed that the statistical results, which confirm experts' intuitions, are valid for the types of problem addressed by their work, and then the model can be altered to reveal this assumption.

Note that under this assumption the only real change in the model occurs in the target function, where all conditions go to zero except those involving the fabric length variables. An alternative way for problem solution is to resolve the linear rest and check the resulting solution for satisfaction of the integer constraints. However, this process is not practicable: for realistically measured problems the amount of variables prohibits explicit computation. Furthermore, most outfits manufacturers who would use these solution methods don't have sufficient computing capacity on site to work with sophisticated integer programming solvers.

Therefore the development of heuristic algorithms to resolve (COP) targets finding computationally reliable methods for finding good (i. e. , relatively low cost) answers to (COP) for a solid group of problem circumstances. They selected two types of algorithm for the introduction of such heuristics, constructive and improvement. A constructive algorithm requires the input data and builds a possible solution using intuition, clues from the spatial areas of the issue, and guidelines found in the numerical model. An improvement algorithm commences with a preexisting possible solution and efforts to change the answer in some manner so that the price tag on the perfect solution is is reduced while feasibility is retained. The worthiness of the price function associated with the feasible solution produced by one of these heuristic methods may then be weighed against some numerical bound, or other benchmark alternatives.


CutPlanner is a software package for use in the textile developing industry for computerized slice order planning. CutPlanner takes a customer's order for a clothing item and creates a cut arrange for that item, including different sizes and different cloth types or colors, which decreases production costs. A cut plan can be an project of sizes and textile types to markers. For each of the markers, the mandatory amount of plies is computed to fulfill the order's specifics. The objective of CutPlanner is to minimize total development costs. They consist of the expenses for the textile used, and several development costs incurred by causing the markers, planning of the reducing process, and the picking of pieces to be cut

CutPlanner provides two different methods of procedure to calculate materials consumption:

1. Conventional setting: The user dictates the approximated yield ideals that designate the material ingestion, which is determined by the number of sizes in a marker.

2. Exact mode: CutPlanner engages an integrated automated marker making engine to calculate the true material intake. Here, the user doesn't have to provide any estimations: the program operates automatically.

Genetic marketing of fabric utilization in apparel production.

In apparel making, trim order planning (COP) takes on a substantial role in controlling the price of materials as cloth usually occupies more than 50% of the full total manufacturing cost. Following information on retail purchases in conditions of variety, size and color, COP seeks to minimize the total creation costs by growing feasible cutting order plans regarding material, machine and labour. A hereditary optimized decision-making model using adaptive evolutionary strategies is suggested to assist the development management of the outfits industry in the decision-making process of COP when a new encoding method with a shortened binary string is devised. Four collections of real creation data were gathered to validate the proposed decision support method. The experimental results illustrate that the proposed method can reduce both the materials costs and the production of additional clothing while satisfying enough time constraints placed by the downstream sewing department. Although the full total procedure time used is much longer than that using professional practice, the great benefits obtained by less fabric cost and further quantity of clothing designed and produced largely outweigh the longer procedure time required.

Cut order planning

Cut order planning (COP) is the first level in the development workflow of the apparel processing company. It really is a planning process to determine how many markers are needed, how many of each size of garment should maintain each marker and the number of fabric plies that will be lower from each marker. Marker is the productivity of the procedure of marker planning, which is the procedure following the COP. Planning process using commercial computing to set up all patterns of the component elements of a number of garments on a bit of marker paper, . Pursuing marker planning, the third operation is textile spreading, which really is a process by which fabric items are superimposed to become fabric lay on the cutting table. The last operation is textile cutting. Garment pieces are cut out of the fabric lay following routine lines of the component parts of one or more clothing on the marker, and then transported to the sewing team for assembling to be a finished garment.

COP, the most upstream activity, plays a significant role in influencing the fabric material cost and the creation cost in the clipping department. Predicated on the requirements of customer requests in terms of style, volume, size and shade, it seeks to minimize the total production cost by producing cutting orders with respect to material, machine and labour.

In the cutting room, following the conclusion of COP and marker planning, distributing and chopping are then carried out, and the time and costs required for these two procedures will be affected by the quality of the slice order strategies being developed. An excellent plan can increase the rate of textile utilization.

The COP usually starts with a retail order comprising the quantities, sizes and colors of garments to be produced. The next example demonstrates how a lower order plan is derived. For convenience, only the levels of apparel and sizes are considered. The facts of the customer order are the following:





Quantity (in portions)




The constraints on fabric lay sizes are:

Maximum quantity of plies for each place: 75

Maximum quantity of garments marked on each marker: 5.

The maximum number of clothes produced per lay down is 5-75=375 pieces and the number of clothing required by the customers is 300+600+400=1300 portions. Therefore, the theoretical bare minimum volume of lays is add up to 1300/375=3. 47. Thus giving a practical minimum of four lays to cut the order. In case the order is to be cut at the cheapest cost, the lays need to be as long and deep as you can. Among the possible solutions is:






Lay 1: 60 plies






Lay 2: 75 plies






Lay 3: 75 plies






Lay 4: 50 plies

An substitute of lay 1 is to truly have a four-garment marker and also to spread 75 plies. This might reduce the trimming cost but was turned down because of the cloth cost since there would be 15 more plies and high fabric end loss, which occurs on both end of every cloth ply (more plies suggest greater end reduction). This solution has exhibited that sizes Medium and Large are in the ratio of 3:2. The marker for lay down 2 can even be used for lays 3 and 4, thus lowering the expenses of marker making.

This example shows that numerous other possible COP solutions can be made. The COP problem becomes more difficult when the numbers of garments and sizes increase. The issue will be further complicated when the parameter of color is also considered in the plan. In addition, labors are needed to operate the growing and reducing machines. As the fabric cut bits will be carried to the sewing room for garment assemblage, COP must consider the fulfillment of the demand quantity of cut piece from the downstream sewing room.

Current industry methods in generating the COP range from manual ad hoc procedures by cut order planners to commercial software. However, many attire manufacturers are still using alternatively primitive methods; they count mainly on the expertise and subjective analysis of the planners to produce the plans. Therefore, the optimal COP cannot continually be assured. Commercial COP software is available for use, but the COP heuristics are usually placed by the proprietors as private. Apart from generating a COP with the right level of apparel with right size and coloring, there is certainly little room for lessening material, machine and labor costs.

Near-optimal COP solutions to reduce both materials and labour and machine costs using a genetic search engine optimization model based on adaptive evolutionary strategies. The objective is to aid the production management of the clothing industry in the COP decision-making process and increase the quality of the decisions. It's been remarked that the COP problem is NP-completeness in nature and it is feasible to employ a heuristic method of solve the condition consequently by using constructive heuristics with intuition start and fine-tuning the perfect solution is with another improvement heuristic (Jacobs-Blecha et al. , 1998).

Roll Planning of textile spreading

In the procedure of fabric growing, the variance of cloth yardage between fabric rolls can lead to a notable difference in fabric damage during spreading. As you'll find so many combinations the arrangement of the fabric roll sequences for every cutting lay down, it is difficult to construct a roll planning to minimise the textile wastage during growing in apparel making. Recent advancements in computing technology, especially in the area of computational brains, may be used to handle this problem. Among the various computational cleverness techniques, hereditary algorithms (GA) are particularly appropriate. GAs are probabilistic search methods that hire a search technique predicated on ideas from natural genetics and evolutionary principles. This paper presents the facts of GA and clarifies how the condition of move planning can be designed for GA to solve. The consequence of the study shows that an optimal roll planning can be exercised by using GA way. It is possible to save a considerable amount of textile when the best spin planning can be used for the creation.

In clothing development, the textile cost alone is about 35-40 percent of the value of your garment, this is the major cost item in clothing product. Lately, the price tag on cloth has increased continually, so a certain percent decrease in textile cost would influence the total processing cost. The textile spreading and trimming is the major development process that can determine the material usage as well as the completed quality of the garment. In addition to the fabric loss due to the fabric flaws, there are two factors behind fabric loss in the production process:

(1) marking reduction or marker fallout, which is formed because of the spaces and other non-usable areas that happen between the garment panels of an marker; and

(2) spreading reduction, which is the fabric loss that prevails during the spreading process apart from the loss caused by the marker layout; these include the finish loss, width loss, splicing damage and remnant damage.

Although marker planning is always the major determinant of material utilisation, it is also important to plan and control the growing process carefully to be able to minimise the distributing loss. Along the way of fabric growing, the yardage level of one fabric move usually is insufficient for the necessity of a trimming lay. Therefore, the yardage volume required for each and every cutting place normally will come from several rolls of fabric. Generally, there's a variance on the fabric yardage on each textile spin. Garment manufacturers usually acknowledge this structure of cloth delivery so long as the total amount of fabric delivered is correct. In case the yardage of each fabric move is not the same, the sequence of combining the fabric rolls for every single cutting lay may lead to various spreading loss. As you'll find so many mixtures of the design of the cloth roll sequences, it's very difficult for the providers or supervisors in the clipping room to determine an optimal cloth roll series for a lowering lay for lessening the spreading loss. In practice, the operator or supervisor in the clipping room usually selects the cloth rolls randomly without the roll planning in the growing process. With regards to the numerical model that can anticipate the quantity of materials wastage of a particular lay during textile spreading, this paper introduces a fresh approach to take care of the condition in roll planning by using genetic algorithms. This system could effectively deciding the optimal collection of fabric rolls for every cutting lay to be able to minimise the textile loss during growing.

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