Practical Garment Production Process – A Case Study
End-to-End detailed garment production process
This project work deals with the productivity and quality enhancement in a garment manufacturing unit through a practical study conducted in the stitching department.
Sampling Department
After the confirmation of the order, each sample sent to the buyer has the following details attached to it, with the help of a tag. It contains the details pertaining to both, what the buyer has demanded and what supplement fabric/trims etc. they have used.
- Ref no.
- Colour
- Fabric
- Composition
- Description
- Quantity
- Style no/ Size
- Trims
Sampling Process
The process of the sample department varies from context to context, and the development process covers a wide range of diverse products. There are different phases of sampling; the first phase covers the development of the initial concept or design idea through its approval by the customer and full review/risk analysis by the development and production teams.
The second phase covers the process following acceptance of the first prototype sample and includes the functions of sourcing and ordering components, testing the product and carrying out trails once the finalized sample specifications have been drawn up, the third and final phase commences. The phase includes a range of activities that are carried out before large scale or bulk production capacity outside the home producer/developers wherever this is applicable.
Development samples or inquiry samples
When they work with some buyers continuously, they have to keep on sending samples to them very often. Whenever they have inquiries, the buyer needs samples. Buyers like to see the garments in new fabric. For one inquiry, they need samples of different fabrics to choose from. If they want to develop a new style of new fabric, then also they have to send these samples.
Salesmen samples or promotional samples
Some buyer needs these samples for getting the orders from their customers. If the buyer is having 7 salesmen in his office, then the buyer will ask us to make 7 samples in each style. The salesmen book the orders from their customers, by showing these samples. Buyer places the order to them accumulating the quantities.
If they sent samples for 5 styles, sometimes, they may get orders for all 5 styles, 3 styles or 1 style. Sometimes, they may not get an order for even a single style. Expected sales may not be possible, due to poor quality, unsuitable colours, improper measurements, unmatched prints or embroidery, etc. of salesmen samples. Or it may be due to local business recession or competition or unsuitable prices. Anyway, they have to make these salesmen samples perfectly with a sincere interest to get orders.
Photo samples or fit samples
These samples are to be made after getting the order sheets. These samples are needed to check the measurements, style, and fit. So they can be made in available similar fabrics but in the actual measurements and specifications.
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Some buyers may need these samples if they want to print the photos of garments on photo inlays, packing boxes, hangtag, etc. These samples may be needed for local advertisements or buyer’s promotional occasions.
Pre-production samples
These samples are almost like approval samples. They made it on actual production fabric with actual bulk trims. They represent that the product will be like these samples.
Shipment samples
These samples are sent after shipment. They sent it in actual packing with all labels, tags, etc. Generally, these samples will not be tested by the buyer for anything. And even if they get some comments from buyers, they can save their selves by saying that these samples were sent from the leftover garments after the shipment; hence there might be some mistakes
Fabric Store
Based on the fabric consumption, total fabric requirement is generated for an order and the same is sourced from the pre-approved fabric supplier. The fabrics are in-house in the factory.
The fabric is required to check 100% of other sellers or can be 10% only in case of fabric sourced from its own mill. For example, the 4 Point System is used by the factories for fabric inspection.
Some fabric tests like fabric GSM, fabric shrinkage and colour 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.
It is common that when fabrics are sourced in bulk, the fabrics are processed in different lots (batches) depending on dyeing machine capacity. So, there are having shade variations of fabrics of the same colours. To avoid shade variation in garments shade band is prepared by the factory.
Fabric suppliers
- Banswara Mills- Rajasthan
- Arvind Lifestyle- Bangalore
- Arvind Ltd- Madhya Pradesh
- Raymond Ltd- Mumbai
- Raymond Apparel Ltd- Chindwara
- Bombay Rayon Fashion- Boisar
- Reliance Ltd- Mumbai
- Savika Fashion- Mumbai
- SVG- Ahmedabad
- Bhagwan Enterprises- Mumbai
- RSWM- Rajasthan
- Blue Fab- Mumbai
- Nahar Mills- Chandigarh
- Donear- Surat
- Aditya Birla- Bangalore
- Auro Textiles- Baddi
- Dee Jay International- New Delhi
- Grasim- Haryana
- Banswara Mill
- Nihalchal
- Raymond Luxury
- Raymond Limited
- Auro Textile
- Vardhman
- Punit Export
- Nahar Industrial
- O.C.M
Types of fabric
- Woven
- Polyester Viscose lycra
- Cotton Polyester
- Polyester Viscose
- Polyester blended wool
- PV
- Lycra
- Cotton
- Woolen
- Velvet
- Knitted
- Cotton-lycra
Types of Fusing
- Lapel Fusing
- Body Net
- Belt Canvas
- Microdot
- R Fusing
