Process of apparel

manufacturing

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 oversees
both 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 the
buyer.
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PRE-DEVELOPMENT

POSTDEVELOPMENT

The Idea

Fabric is sourced and

approved by buyer

-Buyers need
-Merchandisers and
designer ideas
Ideas developed into
sketches
Fabrics and other
trims are ordered for
first sample
Cost estimation
(Quick-costing)

PPC department sets

production schedule

Fabrics and other

trims for sampling are
ordered
Pattern development
for sample

Sample developed &

reviewed

First pattern is
developed

Fit sample is
developed &
reviewed

First samplePrototype is
developed

Production pattern is
finalized

Proto sample
reviewed
Additions/changes
made as per buyers
need
Second Prptotype
is prepared

Logistics decides the

line set-up
Production package is
forwarded to
production manager

PRODUCTION

Fabric in-housed and

inspected
Fabric sent to cutting
room-spread and
garments cut out

Grading details sent

by the buyer
Pattern is
graded

Cut garments go to
sewing operations
and assembled

Garments are given

final production
details and pressed

Sizeset developed
and reviewed

Additions/changes
made as per buyers
need

Buyer sends the

sealer sample-pre
production sample
finalized

Sample finalized &

Buyer places order

Production marker is
made

Final quality checks

and finishing

Tagging and packing

of the garments

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Buyers QC inspection

Ready for shipment

Product Development stages

Pre Development Stage

Post Development Stage

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Pre Development Stage

Concept development : Acc. to buyers needs

a well targeted product assortment is
selected.
Pattern making for prototype, costing
Review on prototype
Decisions about styling, production feasibility,
fabric sourcing etc.
Final placement of order by the buyer
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Post Development Stage

Styling and fit are perfected for the final production

Making Production Pattern
Pattern Grading
Marker Making
Ordering of Production Fabrics
Production Planning
Final Costing
Production
Shipping
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Merchandising & Sampling

Communication with the buyer

Identifying their needs and choices
Sampling Based on the Buyers Preference
Approval of Sample by Buyer
Getting Buying Order
Getting pattern made for sample for final
production
Developing and maintaining production
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Sampling Stages

Development Stage Samples

Prototype Sample
Fit Sample
Salesman Sample
Size Set
Pre Production Sample

Production Stage Samples

Top of Production Sample

Shipment Sample

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Development Stage Samples

Proto Sample: Communicates design of a style. (Fit and

Fabric are not important)

Fit Sample: Made with actual measurements (Extremely

important)

Salesman Sample: Displayed for assessing customer's

feedback to forecast demand. (actual fabric and trims)

Size Set Sample: Check fit of the garment in different sizes

(Jump Sizes)

Pre Production Sample: Made in actual production line

(actual fabric, trims and accessories) Production can be started only

after approval of PP sample

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Production Stage Samples

Top of Production: Few pieces taken out in the middle of

the production, sent to buyer as TOP sample.

Shipment Sample: 2-3 finished and packed pieces with all

packing details are kept for future reference. Shipment sample is
kept by factory merchants and buyer's merchant

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Sourcing & Store Processes

Getting Requisition For Sourcing The Fabric And

Accessories
Communication With Suppliers For Getting The Best
Quality At Competitive Prices And Placing The Order
Follow Up For Timely Delivery Of Goods
Receiving And Unloading The Fabric And Accessories
Quality Checking Of Material
Getting Requisition from Production Department
Issuing The Material According To The Requisition
Managing Records At Every Level

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Production

Cutting Room
Sewing Room

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Cutting Room
Cutting is a process of separating parts from the
fabric as replicas of the pattern pieces in the marker
for assembly operations.
Activities in cutting room:
Marker Planning
Spreading
Cutting
Fusing
Sorting & Ticketing
Cut Panel Checking
Bundling

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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 components
acceptable for assembly.

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Positioning the marker

Positioning the marker is the process of

placing the marker plan on the top of the lay
and securing it with adhesive to prevent its
movement during cutting

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Cutting

The lay is cut with help of electrically

powered cutting machines.
The machine is moved through the lay
following the pattern lines of the marker

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Sorting and Ticketing

The pieces cut out from the lay are now

sorted out size wise.
All the components of one garment size are
brought together.
It is very important to take care that pieces
cut from two different bolts (bundles) of fabric
are not mixed up

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Ticketing is the process of marking the cut

components for shade matching precision,
and sequence identification.
The ticket contains the size, bundle number
and piece number and serves as important
means to track the parts of the garment in the
assembly line from start to the end.

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Cut panel checking

The ticketed panels are now sent to the

checking area for inspection of every
individual piece for any objectionable faults

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Bundling

The checked components of one style and in

one size are now clubbed and bundled using
ties.
The size of the bundle depends upon the
requirement of the production plant. Each
bundle will contain pieces of same style and
same size only.

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EMBOIDERY AND
PRINTING

The cutting department is responsible for

sending the cut components of a style for
embroidery or printing as stated in the
production package

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FUSING

The parts to be fused are separated from the

bundle.
The interlining is cut according to the size of
the components to be fused.
By means of temperature and pressure
fusing takes place at a particular speed and
for a particular time.

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Sewing Room

Place where sewing machinery is arranged to bring

together pieces of fabric to stitch into the desired
product in the most efficient way.
The production department works hand in hand with
the fabric store (for issue of fabric to the cutting
department), trims store (for issue of trims), cutting
(for getting the fabric cut), merchandising (for the
production package and details), sampling (for
production samples), logistics (for allocation and
scheduling), quality and all other departments to get
the right product made.
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Finishing

Cutting of Extra Threads

Washing
Ironing
Initial Quality Checking
Finishing
Spotting
Mending
Final Checking
Ironing
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Packaging & Dispatch of

Goods

Folding
Putting accessories like tags, clips etc.
Putting folded garment in to polythene
Making Blister Pack Of Packed Garments
Putting Blister Packs Into Boxes
Stripping Of Boxes
Weighing Of Boxes
Handing Over To The Shipper
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Documentation
Quality Control
Administration & Acccounts

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