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Process of apparelmanufacturing
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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
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