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.