Abstract <p>The understanding of the dynamics of apparel wastage is of paramount importance not only to attain sustainable industrial growth but also to cater ecological harmony. This article aims at the elaborative accountability of cut-and-sew losses in cutting room with respect to four categories: splice loss, remnant loss, buffer loss and width loss. This research contributes towards the existing literature on three major fronts that is, (i) – derivation of mathematical functionals to quantify the losses, (ii) – determining the factors generating these losses, and (iii) – estimation of cause-and-effect relationship. The outcomes of this research are based on 1728 observation regarding each loss. The experimental data are realized through the launch of well-structured full factorial design involving thoughtfully nominated risk factors as explanatory variables. The analysis of the data reveals that the cutting room losses are dominated by the losses inside marker application that is the buffer loss is estimated to contribute 90% of total volume of cutting room loss. Whereas, the share of remnant loss, width loss and splice loss are estimated to be 4.6%, 3.2% and 2% in the total loss volume, respectively. Also, the model-based examination of the loss data shows the defining significance of risk factors such as, garment type, garment style, garment sizes, edge alignment and marker width.</p> Graphical abstract <p></p>