apparel manufacturing process[1]

8/16/2019 Apparel Manufacturing Process[1]

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Process of apparelmanufacturing


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Garima Agarwal

Apparel Manufacturer

An Apparel Manufacturer coordinates the

entire production of an item or a line of

clothing and prepares it for delivery to retail

stores. An Apparel Manufacturer overseesboth the production process and the

contractors to ensure delivery dates


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Similar general processes of garment

production in different companies

Difference exists in how the processes are

organized and how they occur within the

industry.

Activities are built around activities of an

export house the needs and demands of thebuyer.


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PRE-DEVELOPMENT

The Idea-Buyer’s need

-Merchandiser’s anddesigner ideas

Ideas developed intosketches

Fabrics and othertrims are ordered for

rst sample

Cost estimation(uick-costi

ng!

Fabric sent to cuttingroom-spread andgarments cut out

Buyer sends thesealer sample-pre

production sample nali"ed

Fabrics and othertrims for sampling are

ordered

#dditions$changesmade as per buyer’s

need

First sample-Prototype is

developed

%roto samplerevie&ed

Second Prptotypeis prepared

#dditions$changesmade as per buyer’s

need

'ample nali"ed Buyer places order

POST-DEVELOPMENT

%attern developmentfor sample

Fit sample isdeveloped

revie&ed

'ample developed revie&ed

%roduction pattern isnali"ed

First pattern isdeve

loped

)rading details sentby the buyer

%attern is

graded

Sieset developedand revie&ed

Fabric is sourced andapproved by buyer

%roduction package isfor&arded to

production manager

%%C department setsproduction schedule

Final *uality checksand nishing

+ogistics decides theline set-up

Fabric in-housed andinspected

Cut garments go tose&ing operations

and assembled

)arments are givennal productiondetails and pressed

Buyer’s C inspection

Ready !or shipment

PROD"#TION

,agging and packingof the garments

%roduction marker ismade


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Pre Development Stage

oncept development ! Acc. to buyer"s needs

a well targeted product assortment is

selected.

Pattern ma#ing for prototype$ costing

%eview on prototype

Decisions about styling$ production feasibility$

fabric sourcing etc. &inal placement of order by the buyer


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Post Development Stage

Styling and fit are perfected for the final production

Ma#ing Production Pattern

Pattern Grading

Mar#er Ma#ing 'rdering of Production &abrics

Production Planning

&inal osting Production

Shipping


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Merchandising & Sampling

ommunication with the buyer

(dentifying their needs and choices

Sampling )ased on the )uyer"s Preference

Approval of Sample by )uyer

Getting )uying 'rder

Getting pattern made for sample for finalproduction

Developing and maintaining production


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Development Stage Samples

Proto Sample! ommunicates design of a style. +&it and&abric are not important,

&it Sample! Made with actual measurements +-xtremelyimportant,

Salesman Sample! Displayed for assessing customersfeedbac# to forecast demand. +actual fabric and trims,

Size Set Sample! hec# fit of the garment in different sizes+/ump Sizes,

Pre Production Sample! Made in actual production line+actual fabric$ trims and accessories, Production can be started onlyafter approval of PP sample


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Production Stage Samples

*op of Production! &ew pieces ta#en out in the middle ofthe production$ sent to buyer as *'P sample.

Shipment Sample! 012 finished and pac#ed pieces with all

pac#ing details are #ept for future reference. Shipment sample is#ept by factory merchants and buyers merchant


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Sourcing & Store Processes

Getting %e3uisition &or Sourcing *he &abric And Accessories

ommunication 4ith Suppliers &or Getting *he )est5uality At ompetitive Prices And Placing *he 'rder

&ollow 6p &or *imely Delivery 'f Goods %eceiving And 6nloading *he &abric And Accessories

5uality hec#ing 'f Material Getting %e3uisition from Production Department (ssuing *he Material According *o *he %e3uisition Managing %ecords At -very 7evel


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Production

utting %oom

Sewing %oom


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Cutting Room

utting is a process of separating parts from thefabric as replicas of the pattern pieces in the mar#erfor assembly operations.

Activities in cutting room! Mar#er Planning Spreading utting &using Sorting 8 *ic#eting ut Panel hec#ing )undling


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Spreading

Spreading is the process of superimposing

plies of fabric on a horizontal table in a

manner$ which permits these plies to be cut

simultaneously into product componentsacceptable for assembly.


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Cutting

*he lay is cut with help of electrically

powered cutting machines.

*he machine is moved through the lay

following the pattern lines of the mar#er


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Sorting and Ticketing

*he pieces cut out from the lay are now

sorted out size wise.

All the components of one garment size are

brought together.

(t is very important to ta#e care that pieces

cut from two different bolts +bundles, of fabric

are not mixed up


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*ic#eting is the process of mar#ing the cut

components for shade matching precision$

and se3uence identification.

*he tic#et contains the size$ bundle numberand piece number and serves as important

means to trac# the parts of the garment in the

assembly line from start to the end.


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Cut panel checking

*he tic#eted panels are now sent to the

chec#ing area for inspection of every

individual piece for any ob9ectionable faults


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Bundling

*he chec#ed components of one style and in

one size are now clubbed and bundled using

ties.

*he size of the bundle depends upon there3uirement of the production plant. -ach

bundle will contain pieces of same style and

same size only.


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EMBOIDERY ANDPRINTING *he cutting department is responsible for

sending the cut components of a style for

embroidery or printing as stated in the

production pac#age


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!SING

*he parts to be fused are separated from the

bundle.

*he interlining is cut according to the size of

the components to be fused. )y means of temperature and pressure

fusing ta#es place at a particular speed and

for a particular time.


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Sewing Room

Place where sewing machinery is arranged to bringtogether pieces of fabric to stitch into the desiredproduct in the most efficient way.

*he production department wor#s hand in hand withthe fabric store +for issue of fabric to the cuttingdepartment,$ trims store +for issue of trims,$ cutting+for getting the fabric cut,$ merchandising +for theproduction pac#age and details,$ sampling +for

production samples,$ logistics +for allocation andscheduling,$ 3uality and all other departments to getthe right product made.


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Finishing

utting of -xtra *hreads 4ashing (roning (nitial 5uality hec#ing &inishing Spotting

Mending &inal hec#ing (roning


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Packaging & Dispatch ofGoods &olding

Putting accessories li#e tags$ clips etc.

Putting folded garment in to polythene

Ma#ing )lister Pac# 'f Pac#ed Garments

Putting )lister Pac#s (nto )oxes

Stripping 'f )oxes 4eighing 'f )oxes

:anding 'ver *o *he Shipper


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Documentation

5uality ontrol

Administration 8 Acccounts

apparel manufacturing process[1]

Documents