Our aim is to produce quality products in the
shortest possible time. As a garment manufacturer, we purchase fabric from
various fabric suppliers. Prior to sourcing the fabric, there are some pre-production processes handled by the factory merchandiser.
Following steps are involved in the
pre-production stage.
- Pattern
making,
- Garment
sampling,
- Fabric
development,
- Fabrics
and trims approvals,
- Fabric
and trims sourcing,
- PP
meeting
Pattern Making
From the design sketch and product specification
sheet, garment patterns are made by the pattern master. The first pattern of a
design is made at the time of prototype making. We also incorporate CAD systems
for making the patterns. The CAD system has another advantage in marker making,
instead of manual marker making, marker papers are printed by a plotter. The
markers are efficiently made by CAD system and fabric utilization can be
improved. The patterns are modified and corrected as the sample development progressed
and patterns are graded during size set sample making. The final patterns are
approved after the PP
sample approval.
Garment Sampling
We develop garment samples and take approvals on
the sample from our clients. Without sample approval, the factory is not
allowed to start the bulk process. We develop various types of samples at
various stages of sample development.
We make sure to follow the product tech pack to
prepare the garment sample as well as the bulk production.
In the sampling stage, the factory learns the
garment construction details and material required for a given order. The
sampling department is also working as a research and development (R&D)
section for the factory. The sampling process helps the production team start
the bulk production without many issues.
A pre-production meeting is conducted at the
factory by the merchandising team. In this meeting product design, production
schedule and responsibilities, buyer requirement in all aspects of product
quality, and production completion deadline are discussed.
Fabric Development
Textile fabrics are available in three main
categories - knitted, woven and non-woven fabrics. The factory makes fabric
selection based on fabric quality required, like fabric color, fibre content,
surface texture, hand feel, physical and chemical properties.
When the fabric selection is made Lab dip and
desk loom are developed at this stage prior to bulk fabric order. Prior to bulk
sourcing, fabric sample is tested to check whether the desired quality is
matched with the developed fabric or not. For yarn dyed stripes knits fabric
knit-down is developed.
Bulk Fabric
Sourcing
Fabric sourcing: How much fabric is required for each garment? What
is the average fabric consumption for bulk production? At this stage, there are
few calculations on fabric consumption per garment. This work is done by
pattern making department (CAD department). Based on the fabric consumption,
total fabric requirement is generated for an order and the same is sourced from
the pre-approved fabric supplier.
Fabric quality inspection: Whether the fabrics are
purchased from the buyer nominated fabric suppliers or from the open market, We
cannot be sure whether all the fabrics are without fault and defect free. So
fabric checking is an important process. The fabric may be required to check
100% or can be checked randomly based on fabric quality received. For an
example, 4 Point System is used
by the factories for fabric inspection and fabric quality grading.
Some fabric tests like fabric GSM, fabric
shrinkage and color bleeding in washing are done by the factory. If the fabric
shrinkage is more than the allowance, fabrics are pre-shrunk for bulk cutting.
Sometimes patterns are modified according to the fabric shrinkage which gives
the correct measurement in the garment after washing.
Fabric sorting and shade banding: It is a common fact that when fabrics are
sourced in bulk, the fabrics are processed in different lots (batches)
depending on dyeing machine capacity. So, there’re chances of having shade variations of
fabrics of the same colors. To avoid shade variation in garments shade band is
prepared by the factory.
Sourcing for trims and accessories: Similar to fabric sourcing all required trims
and accessories are purchased. Trims and accessories are sourced in advance to
production start. Trims requirement is calculated based on the trims
consumption per garment.
Quality checking of trims and accessories: The quality of the trims are inspected and
approved for production. Trims like laces, twill tapes, buttons, zippers, and
drawcords are tested for color bleeding. Defective and damaged trims are
separated and are not used in garments.
Production Planning
All the processes
and activities are planned and scheduled in advance by the production planner.
The production planning team executes and controls production activities. They
keep track of the actual process activities to ensure on-time order completion.
A time and action calendar is prepared by the planning team for production
scheduling and controlling. Mostly the T&A is made by a merchandiser.
Cutting Process
The bulk cutting is done by means of cutting machines. Before
the cutting of fabric, cut order plan is prepared and the fabric is taken from
the fabric store according to the requirement. The following steps are followed
in the cutting section.
Fabric spreading
Marker making
Component numbering on the marker
Lay Cutting
Ply numbering
Sorting and Bundling
Dispatch cuttings to stitching section
Quality
checking in cutting section
Garment
Printing and Embroidery
Printing and embroidery processes are value-added
but optional process. Printing on the garment is done at either the fabric
stage or after cutting of garment components.
Garment Stitching
After the cutting and printing process (optional
process), cut components are sent to the sewing department. Operators stitch
and assemble garment components one by one and make the garment stitching process involved the following sub-processes.
- Part
preparation
- Marking
- Folding
and pressing
- Stitching/assembling
- Quality
checking
In the sewing section, operators are also
provided various sewing supplies like stitching threads, sewing machine
needles, trims, operation-specific guides, and attachments.
Garment Washing
Washing is done to remove dirt and dust from the garments. The washing process involves additional cost, so this process is done only if the client requires it. More than just cleaning of garments, washing is also done to give a washed look to the finished garment with different types of finishes.
Garment
Finishing
Here is a brief list
of garment finishing processes.
Thread trimming
Removing the sticker and loose threads
Initial garment checking
Garment pressing
Final garment checking:
Garment folding and packing
Folding: The finished garments are then folded in a
specific dimension. Folding can be done by using a template if required. The
price tags, hang hags and any other kind of tags are attached to garment after
folding. The garment folding types varied depending on the article and buyers
requirement. Sometimes the whole garment is packed in a hanger without folding.
Packing: The folded garment is packed into a poly bag to keep it fresh till it
reached to the retail showroom. Different types of packing accessories are used
to keep the garment in a desired shape. Some products are packed into
paperboard cartons directly without packing it into a poly bag.
Carton packing: For the transport of the finished garment are packed into bigger
cartons.
Internal Audit: The packed garments are then inspected for quality assurance of
the outgoing finished products. This process is followed for internal quality
audit and to ensure that no defective garments are packed into the cartons.
Finished and ready product: Finally the garments are ready for the shipment
and ready for the end consumers.