[Blog]()Production # Footwear production: size runs, pairs and material consumption Forty-eight correct pairs in total can still be the wrong size run when variants do not match. **[Jonathan Perez]()**Co-founder · Design, product and sales October 8, 2026 · 8 min read **Short answer** Define the run by model, color and size, calculating materials from the recipe for each variant. Record pairs and individual pieces with explicit units; check progress and remaining quantities by size. Treat net material use versus standard as a difference to investigate, rather than labeling every mismatch scrap or duplicating pairs when closure is retried. ## Size run, pairs and net material use Ten tests of variant mix, weighted use, revision, partial delivery and unduplicated pairs. [Download CSV worksheet]() In this guide - [What identifies the size run you must deliver?]() - [Example: forty-eight pairs need a weighted sum]() - [Does a pattern calculation equal actual consumption?]() - [What does a partial delivery demonstrate?]() - [Which tests must pass by variant?]() - [What should you bring to a diagnosis?]() ## What identifies the size run you must deliver? Relate order, model, color, sizing system and pair quantity by variant. Numbering needs a catalog: do not assume equivalence between different systems' labels. Distinguish pair, individual shoe, component and box. Two left shoes of the same size do not form a complete pair; record pending sides when the process handles individual pieces before matching. Grupo ZAS publishes recipes and consumption by model, size and color alongside size-curve features. [Footwear ERP features](). This description helps compare coverage but does not prove any production total respects your curve. Ask for a case with enough overall quantity but a requested size missing. ## Example: forty-eight pairs need a weighted sum **Synthetic model M48** One model and color require 48 pairs. Sizes are local exercise labels, not an international conversion. Consumption in m² per pair is an illustrative standard, not measured cutting yield. | Size |Pairs |m² per pair |Subtotal m² | | --- | --- | --- | --- | | 24 |8 |0.18 |1.44 | | 25 |16 |0.19 |3.04 | | 26 |16 |0.20 |3.20 | | 27 |8 |0.21 |1.68 | | Total |48 |By variant |9.36 | The reference is 8×0.18 + 16×0.19 + 16×0.20 + 8×0.21 = 9.36 m². An average ignoring the mix may produce a different requirement. If four size-24 pairs change to size 26 before release, the total remains forty-eight, but the reference rises by 0.08: subtract 0.72 and add 0.80, reaching 9.44 m². Retain revision and authorization; do not silently change a run whose material has already been cut. ## Does a pattern calculation equal actual consumption? INESCOP publishes size grading and material calculation methods in Icad Discovery along with manufacturing documentation. [Grading and consumption](). Select the relevant method for leather, synthetic or another form and retain its reference. A design result and actual warehouse issue are different records. Verify which file or interface transfers model, size, unit and revision; a CAD logo does not establish integration. For the original M48 run, 11 m² are issued and 0.60 return unused: net consumption is 10.40. Against the 9.36 standard, the difference is 1.04 m². That does not establish waste by itself: it may include pending remnants, setup, material defects or an incorrect entry. Classify destinations and use a consistent unit. Do not add linear meters, area and piece counts without explicit relationships. ## What does a partial delivery demonstrate? An initial twenty-four pairs with sizes 24/25/26/27 in quantities 4/8/8/4 leaves 4/8/8/4 pending. If all twenty-four were size 25, the overall partial quantity would not show the mix is correct. Retain progress by stage and accepted quantity by variant; completed cutting is not a finished pair or delivered order. Incompatible sides or colors remain held for review. Business Central documents materials versions with validity dates. [Recipe versions](). This is a configuration-dependent product reference. A policy preserving an already released footwear recipe needs testing; it does not imply Nightly has implemented CAD, grading or that control in a factory. ## Which tests must pass by variant? - Normal: M48 retains 8/16/16/8 and calculates 9.36 m² with its revision; partial delivery leaves size-specific pending quantities. - Exception: a correct total with the wrong size or color cannot appear as a fully accepted run. - Units: pairs and individual shoes remain distinct; an incompatible match cannot be released. - Material: 11 issued minus 0.60 returned gives 10.40 net, with the 1.04 difference awaiting explanation. - Retry: repeating closure F24 neither adds another twenty-four pairs nor consumes their material again. ## What should you bring to a diagnosis? Complete the [size-run and material worksheet](). [Materials revisions]() cover recipe changes; [scrap accounting]() explains material destinations. To scope [footwear manufacturing software](), bring a real size run, partial delivery and warehouse consumption. The discussion starts with verifiable quantities and the process that needs connecting. ## Bring a size run and its material issue In a free diagnosis we can review where the relationship between size, recipe, progress and consumption is lost. - An order by model, color and size with pair quantities. - The size-specific recipe or consumption report and revision. - A partial delivery and material movements with unused returns. [Book a free consultation]()[Ask on WhatsApp]() Related - [Footwear manufacturing software]() - [Production control]() ## Frequently asked questions ### Is tracking total order pairs enough? No. Required sizes and colors must match. A correct total can conceal an excess of one variant and shortage of another. ### Can I use average consumption for every size? Only if your technical criterion supports it and it is identified as such. The example uses different standards and calculates a weighted sum by run. ### Is the difference between standard and net use scrap? It is a difference to investigate. Classify remnants, losses, setup and errors before assigning a cause or disposition. ### Do two shoes count as a pair? Only when they meet defined matching rules: compatible sides, size, model and color. The system must distinguish individual pieces from accepted pairs. ## Sources 1. [Icad Discovery: size grading and material calculations]()INESCOP Solutions / Icad 2. [Footwear ERP: size curves and materials]()Grupo ZAS 3. [Production bill of materials versions]()Microsoft Learn Last updated: October 8, 2026 ## Keep reading [ProductionOct 8, 2026 ### Bill of materials: revisions that preserve work already underway]()[ProductionOct 8, 2026 ### Production scrap: consumption, loss and recoverable material]()[ProductionOct 8, 2026 ### Production scheduling: dates that respect available capacity]() --- Canonical: https://nightlysoftware.com/en/blog/footwear-size-runs-materials Updated: 2026-10-08 Description: Test pairs by size and color, weighted material use, partial results and unused returns without hiding shortages behind the total.