The process of producing garments can be broken down into several key stages, each playing a crucial role in the overall success of your venture:
Pre-production Planning:
Before diving into the manufacturing process, meticulous planning is essential. This stage involves designing, sourcing materials, and creating a detailed production timeline. It's crucial to outline your goals, budget, and any specific requirements to ensure a smooth transition to the next phase.
Garment Manufacturing Process:
This is where your designs come to life. From pattern-making to cutting and sewing, understanding the manufacturing process is pivotal. Collaboration with skilled artisans or factories is key to achieving the desired quality and craftsmanship for your clothing production.
Quality Control:
Maintaining high-quality standards is non-negotiable. Implementing rigorous quality control measures during and after production ensures that your garments meet the expected standards. This step involves inspecting materials, assessing workmanship, and addressing any discrepancies.
Packaging:
The presentation of your products is as important as the products themselves. Thoughtful packaging not only protects your garments during transit but also serves as a marketing tool. Designing appealing and functional packaging adds value to your brand.
Shipping and Logistics:
Navigating the complexities of shipping and logistics is the final step in bringing your garments to market. Choosing reliable shipping partners, understanding customs regulations, and optimizing your supply chain are crucial for timely and cost-effective delivery.
By understanding and carefully navigating each of these stages, you can streamline the bespoke manufacturing process and set the foundation for a successful clothing brand. This guide will walk you through the intricacies of each phase, providing insights and tips to empower you on your manufacturing journey.
Design:
The first crucial step in fashion production is the design phase. Here, the initial concepts and sketches for a new fashion product or line come to life. During the product design stage, the development of product designs, decoration designs/placements, and measurements (size charts) takes place. This information is then compiled into a specialized document known as tech packs. Despite sounding complex, tech packs are essentially a set of documents created by designers to communicate their designs to manufacturers, enabling them to transform this information into a finished garment. As part of the design phase, obtaining fabric samples, Pantone colour swatches, and sourcing additional trims like labels and zips are essential. Most manufacturers can assist in sourcing fabric samples, but having a rough idea of the desired fabric construction and weight is crucial for selecting the most suitable samples. Decisions on quantities, sizes, and colour breakdowns for each product should also be made during this stage.
Cost of Garment(s):
Once the design phase is complete, and all tech packs have been forwarded to the manufacturer, it's time to gather quotes. The quote should encompass raw material costs, manufacturing labour costs, any associated shipping costs, and printing/embroidery costs. Additionally, it's advisable to inquire about any relevant sampling costs during this stage. This critical stage sets the foundation for the entire production process. By carefully considering design details, material choices, and associated costs, you pave the way for a smooth transition to the next stage of manufacturing. The accuracy and clarity of your tech packs play a pivotal role in ensuring that your vision is accurately translated into the final product.
Sampling:
Prototype Sample:
The prototype sample serves as an initial check of the product design. Unlike the final product, it does not use the correct fabric; instead, available fabric is utilized for this stage. The primary purpose of the prototype sample is to assess and validate the design elements of the product.
Fit Sample:
Designed to evaluate the fit of the product, the fit sample is created using the measurement sheets provided to the manufacturer. Similar to the prototype sample, this stage may also utilize available stock fabric. The focus here is on ensuring that the product aligns with the specified measurements and fits as intended.
Pre-production Sample (PPS):
The pre-production sample marks the final stage before bulk production begins. Upon approval of this sample, the factory proceeds with mass production. The original fabric, along with all specified trims and any embroidery or prints, is used in this sample. The approval of the PPS is a critical milestone, as it indicates that all design and production elements meet the desired standards. Only after PPS approval does the factory commence the full-scale production of the ordered garments.
Sampling is a crucial phase in the pre-production planning stage, allowing you to validate and refine the design before mass production begins. Clear communication with the manufacturer and careful evaluation of each sample ensure that the final product aligns with your vision and quality standards. Additionally, it provides an opportunity to make any necessary adjustments before committing to large-scale production.
Pattern Cutting and Grading:
Following the approval of the Pre-production Sample (PPS), the final measurement sheet is completed to facilitate the cutting and grading of patterns for each size. Patterns serve as guides for manufacturers to cut the fabric accurately, ensuring uniformity across various sizes. This step is crucial and needs to be completed before bulk manufacturing commences.
Printing, Embroidery, and Embellishments:
If you specify printing, embroidery, or embellishments, these processes are typically subcontracted to a trusted printing company. Decoration is applied before the garments are sewn together. Alternatively, you may choose to arrange printing after garment construction, depending on their instructions.
Garment Manufacturing (Cutting and Sewing):The manufacturing process progresses with cutting the fabric, a pivotal step that precedes the actual sewing of garments. Once the fabric is cut, skilled sewing machine operators take over, constructing the garments using specific sewing techniques tailored to different sections of the garment.
Final Washes / Specific Dyeing:
After garment construction, many brands opt for a final wash, commonly known as a garment wash. This step helps pre-shrink the material, minimizing the risk of shrinkage when the customer washes the garment for the first time. This is particularly important for fabrics prone to shrinking, such as 100% cotton. If garment dyeing is required, it is performed after the garment is fully constructed.
This stage is a crucial phase in bringing your designs to life. Precision in pattern cutting and grading ensures consistency across various sizes, while attention to detail in printing, embroidery, and embellishments enhances the visual appeal of the final product. The meticulous processes of cutting and sewing, followed by final washes or specific dyeing, contribute to the overall quality and durability of the garments
Now, let's delve into the critical stage of quality control and testing, acknowledging the inevitable presence of errors in textile manufacturing and the importance of understanding manufacturing tolerance.
Quality Control (QC):
This stage involves meticulous attention to detail. During quality control, random garments are selected for thorough measurement checks against the spec sheet. The fabric's stability and overall quality are scrutinized, and visual inspections are conducted to address minor defects, such as untrimmed threads.
Understanding Manufacturing Tolerance:
In textile manufacturing, the concept of every garment being perfect is unrealistic. Errors are inherent, and it's crucial to discuss the manufacturer's tolerance levels before production commences. Remember, garment manufacturers are human, and establishing reasonable tolerance is essential.
Reasonable Tolerance Levels:
Acknowledging the possibility of errors, it's vital to define acceptable tolerance levels with your manufacturer. This proactive approach helps set realistic expectations and ensures a smoother collaboration. Discussing and aligning on these tolerance levels in advance is a key step in managing quality control effectively.
By recognizing the human element in manufacturing and having clear discussions about acceptable tolerances, you enhance your ability to navigate the quality control process. This not only ensures the best possible outcome for your garments but also fosters a collaborative and understanding relationship with your manufacturing partners.
In the culminating stage of our manufacturing journey, packaging takes centre stage to ensure your commissioned garments reach you in pristine condition.
Customized Packaging:
Aligning with the title, this phase involves the meticulous process of packaging the garments specifically for the person commissioning the production—you. Each garment is thoughtfully placed into individual bags, offering flexibility with options for generic bags or those supplied by you.
Secure Box Packaging:
The journey doesn't end there. These carefully packaged garments are then expertly arranged within sturdy boxes, fortifying their protection for the upcoming shipping endeavour. The emphasis here is to safeguard the garments to ensure they remain protected throughout the shipping journey.
Delivery Methods:
When it comes to delivering your goods, there are different arrangements to consider:
FOB (Free on Board):
This is the most commonly used shipping agreement in garment exports. With FOB, the seller is responsible for the goods until they are loaded onboard the ship or aircraft nominated by the buyer. Once the cargo is on board, the responsibility shifts to the buyer.
CIF (Cost, Insurance, and Freight):
In a CIF agreement, the seller bears the cost of the goods in transit, providing insurance with the buyer as the beneficiary. The risk passes to the buyer as soon as the cargo is on board the ship or aircraft.
Key Differences:
The significant distinction between FOB and CIF agreements lies in the point at which responsibility and liability for goods transfer from the seller to the buyer.
Advantages and Drawbacks:
Each agreement comes with its own set of advantages and drawbacks for both parties involved. FOB transfers responsibility and liability when the shipment reaches the designated point of origin. On the other hand, CIF means the seller is responsible and liable until the goods reach the buyer's chosen destination port. CIF is often considered a more expensive option. Sellers frequently prefer FOB, while buyers may lean towards CIF.
Understanding these shipping agreements is crucial for a smooth and cost-effective delivery process. The choice between FOB and CIF depends on various factors, and it's essential to align with your partners on the most suitable arrangement for your specific circumstances. Let's navigate the seas of logistics to ensure your garments reach their destination seamlessly.