Practical Garment Production Process – A Case Study End-to-End detailed garment production process
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.
Banswara Garments
Banswara Garments is located in Daman and Surat. The garment units are specialized in Trousers, Jackets and Waistcoat production. It makes the offerin of Banswara complete textile vertical. Their team will take you right from conceiving an idea for the fabric to the final product ready to wear in the least possible lead-time.
Capacities
Industry Process Flow
The installed capacity is for about 3, 45,000 pairs of trousers and 37,500 jackets per month. The entire focus of the factory is on producing Trousers and Jackets that are able to match the highest standards of workmanship, quality, and appearance.
Facilities
These factories are equipped with a full complement of machines to be able to manufacture trousers and Jackets of the finest quality. They are doing all their order and material-related work on ERP software VISUAL GEMS. They do all their marking and grading on a CAD system from Rich Peace. The sewing line primarily consists of Juki machines. There are automatic Welting Machines from Durkopp Adler. Curtain Felling Machines from Union Special, Eyelet Buttonhole Machines from Reece and Blind Loop Machines from Maier. The pressing is entirely from Roton D, including leggers, toppers and side seam presses
Product Range
Banswara Garments is specialized in the production of jackets. They are making high-class jackets with all the Fusible that are required in making jackets. Most attractive prices, latest signs and the finest quality are their forte. The products are a class of their own. When it comes to quality and comfort, they can be compared with the best in the world. With innovative styles, they occupy a prominent position in the domestic as well as an international market:
Planning Department
The planning department plans every style to execution the order within the time limit. Without a time frame garments cannot sustain so the industry follows every task by scheduling. Each order has a delivery date & the production plan department follows the production plan on the basis of the delivery date. They know when fabric & trims in-house in the factory will. Basically, some of the fabric & trims come from Local vendors. So, they plan both options on the basis of the delivery date. So the production planning department follows some of the important tasks in the following.
Standard Operating Process
Capacity planning
The production planning department makes the production capacity of a factory because capacity determined need to order or not. If order capacity is full whole the year then does not take over capacity order because it is needed over cost to make extra capacity order. On the other hand, if the capacity order is not full then take more orders to fill the capacity otherwise factory will be a loser by financing. Production planning department informs forecast capacity order to merchandisers & management so they can inform to the buyer for order.
Time & Action
The planning department follows every style as per schedule. Every order has its own time frame & meet delivery time. Every style follows product development to shipment. It is a job task for the planning department otherwise they cannot meet delivery as per the planned schedule. The planning department takes action very styles to follow up within the time & Action calendar.
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DateJune 10July 15July 20Aug 1-4Aug 5-7Aug 8-21Aug 22-24Aug 25-29Aug 30OperationOrder received, Trims ordered, Fabric orderedFabric and Trims in-housePPFabric InspectionCuttingStitchingPress and PackingFinal InspectionDelivery
Table 2.2- Time & Action
Scheduling
The production planning department takes decisions when a style is input into line. On the schedule, they cheek fabric & trims with the store department & Merchandising department. If get on-time in-house every item they can input into line. On the other hand if not get fabric & trims on time they can change the line plan to reduce the cost.
PP Meeting
Production planning department cheek particular style fabric & trims status with store & merchandising department. If every item & approval is done then they co-operation with all related departments like as Merchandising, Production, store, cutting, Finishing, quality & buyer representative to make clear understanding for a particular style for production. Before the PP meeting, they cheek all approval, production file, trim card & ready size set.
Order allocation
The planning department does line allocation for every style. When got any order from the buyer they allocation line plan. Without a line plan, an order cannot smoothly run for production. So order allocation is very important for the planning department.
Manpower &machine allocation
The production planning department takes decisions about how many operators need for a particular style to output. They take a decision line layout for a particular style. And also take decision how many machines need to operate the line. Then they take effective decisions for productivity for a particular style.
Materials planning & In-house
The planning department follows up the fabric & trims follow up with the store & merchandising department so they can pre-plan to effective line planning date.
Delivery Date
The production planning department follows the delivery date of garments. If not maintain the delivery of the garments on time it will be loser planning & fall down of the company. So, every style maintains to meet the delivery of the garments. So, they can make effective decisions for garments delivery.
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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.
Standard Operating Procedure
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Fig 3.3- Tech pack
Fig 3.4- Tech pack
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Fig 3.5- Tech pack
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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.
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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.
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 Store – Standard Operating Procedure
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Fabric suppliers
Types of fabric
Types of Fusing