Garment manufacturing is a complex process. In the garment industry, all operations are performed in various departments. It is impossible to briefly describe apparel production. Garment manufacturing involves a series of steps such as sampling, designing, sampling, marking, cutting, stitching and checking, packaging, finishing, and pressing. This is where raw materials are transformed into finished products. Section by section, we’ll describe the entire process of garment manufacturing.
Flow Diagram of Garment Manufacturing Process:
Design
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Sample
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The Pattern
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Pattern Grading
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Making Markers
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Spreading fabric
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Fabric Cutting
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Bundling and sorting cut fabric
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Print/ Embroidery
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Sew the piece together
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Sewing quality control
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Ironing/Pressing
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Hand Tag/
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Final Inspection
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Packing
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Size-wise cartooning
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Cartoon Inspection
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Warehouse
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Shipment
The garment manufacturing process in different areas of the garment industry is described below:
Section:
When making a garment, there are many samples available.
Samples:
- First pattern sample
- Sample for development
- Second pattern sample
- Counter sample
- Salesman sample
- Photo example
- Approval sample
- Sample for pre-production
- Sample from production
- Sample shipment
Samples with details:
1. First pattern sample:
The buyer can design the garment and then make it into a physical item.
These are the criteria for developing the first sample. To develop it, they must be in a certain order.
2. Sample for Development:
Samples taken from the primary pattern are used to create which sample.
3. Second Pattern Example:
Designers and developers often request changes to the original pattern. The comments are followed up with the second pattern.
4. Counter Sample
If the first pattern is created on the designer’s artwork, a counter sample will be made. It must follow another sample provided by the merchandiser.
5. Salesman Sample:
When PRICE has been confirmed and orders are speculation, a salesman sample is prepared. The buyer met with the customer to record their responses on order quantity, color, size, etc. Finally, they placed the order with their vendor.
6. Photo Example:
Photos of models at SHOOTING for Catalog are reproduced with the actual color and material.
7. Approval Sample
It is sent to the buyer for approval of conformity. The sample will be returned to the garments if it is found with any defects.
8. Pre-Production Sample:
The garments make a sample for buyers when the production accessories are attached to the garments. This is known as a pre-production sample.
9. Production sample:
The buyer is guaranteed that the bulk of the order will be produced according to specifications.
10. Shipping Sample
The sample is sent to the shipping inspector. The buyer is then given the product. Samples are important because shipping inspectors may request a sample.
Section for Cutting:
A single sheet of fabric is one piece. We need to cut fabric when we have garments. The final step after sample, marker and fabric spreading is cutting. Because sewing is the next step.
Once sewing begins, then the other processes begin.
Although there are many methods of cutting. This is a manual process. The master cuts the fabric using a hand-cutting machine. The fabric can be cut on a long, large table.
Fig. Section for garment cutting
Keep the maker paper on the fabric surface. Follow the line with your cutting muster and cut the fabric.
Pattern Making Section
The process of making a pattern is drawing on a flat piece of paper or using flat fabric. Flat paper is used in garment manufacturing. Because patterns can be easily removed from the pattern paper. The pattern-making process in garment industries is done using paper. The pattern should be precise so that the garments are accurate. The buyer gives the size list to the garments. After that, the garments conform to the size and include allowances. Every garment has to have a pattern.
Marker Making Section
The marking process is where each pattern is kept in a long piece of fabric. This factor reduces the amount of fabric that is wasted before it is cut. The fabric’s efficiency is increased by using the marker.
Marker making types:
- Manually marking process
- Computerized marking process
1. Manually marking process:
This is where the man does the making manually. They do not use any computer software. This is because the person who does this will have a lot of experience and know-how to do it. The process of making my garments is done manually.
2. Computerized marking process:
This can be done 100% by computer using CAD (Computer-aided Design) or other software.
The Effect of Marker Making:
- Increase efficiency
- Reduce fabric wastage
- Maximize the use of fabric
Fabric Spreading Section
Fabric is laid on a large table for cutting. Because fabric must be spread properly, if it is not laid correctly, the end product (after cutting) will not be correct. Fabrics can be difficult to make when they are sent for production. Proper fabric spreading is essential for the clothing manufacturers.
Fabric attaching clips are used to fix fabric when it is properly laid. The fabric’s surface can also be protected by marker paper. They attach the fabric to the clip.
Types and applications of fabric spreading systems:
- Automatic
- Manual
1. Automatic:
Automatic fabric spreading is when the fabric is spread automatically on a cutting table.
2. Manual:
Manual fabric spreading is when the fabric is spread manually on a cutting table. They work manually in my factory.
Heat cutting system:
Non-woven fabrics are more slippery than other fabrics so a normal cutter is not recommended. We need to heat cut machines.
Types and methods of cutting
- Manual cutting
- Heat Cutting
- Laser Cutting
1. Manual cutting:
Manual cutting is a man-made process. They cut the fabric manually in my garments. The cutting master gives the instructions to the worker. Workers follow the instructions.
2. Heat cutting:
This is a heat machine that uses a copper coil. The coil became hot by electricity. It cut the fabric. This machine is not designed for cutting cloth fabric. It is intended for making non-woven fabric.
3. Laser Cutting:
For cutting, lower light is used. This cutting method is extremely expensive, but it is very efficient.
Sewing Section
A garment’s sewing is an important aspect. We cannot bring our products to the world without good sewing. Sewing involves joining two pieces of fabric together. Sewing is a process that involves many factors. The sewing section is more than just a fabric join. It is a core component of garment manufacturing.
Quality Section
Each garment must ensure quality first. If garments fail to meet quality standards, then garments will not be able to find quality consignment. This garment has an inspection room. Each buyer will be provided with a Quality manager and high-tech machines.
Fig. Garment inspection
Work of Sewing Quality Inspector:
A Sewing Quality Inspector checks the quality of garments during production. The inspector inspects the product to find any faults. The inspector will immediately send the item to the senior operator of the sewing machine to correct the problem. He or she works for online quality control.
Work of Finishing Quality Inspector:
The Finishing Quality Inspector checks the finished products of garments before they are transferred to the sewing line. It is offline quality control, and the maximum fault was removed. They do not check for critical defects, such as broken needles or insects. Every product is subject to a metal detector.
Final Section:
The finishing department is the one that comes after every department. It plays an equally important role in the final appearance and quality of the garments. The following steps are included in this department.
Packing Section
Our garments can be shipped once they have passed the quality control section. We must pack the product before shipment.
Although it is simple, it is not easy. The first pack the product in a poly-pack, then all the garments are placed in the cartoon. Buyers can also provide a cartoon size. Also, the buyer should indicate how many pieces will be kept in one cartoon in their order form.
Store:
This is where you will find many accessories, trims, and fabric. There are two types of stores: one is a normal store and the other is a machine store.
This is my basic observation of the factory’s work, but they also do some important work like fabric Inspection and machine inspection.
Compliance Section
Workers benefit from compliance. They have the right to their legal rights. Many corporations are committed to compliance. Buyers who are from Europe will want a BSCI report. If they are American buyers, then they request WRAP reports.
Deasil Custom Sewing is a growing industrial sewing contractor. we are hiring experienced Industrial Sewing Machine Operators.
