6 Checklists for Bulk Fabric Cutting

Meeting the planned cut date (PCD) is hard. And you always get urgent note to start bulk cutting.

If you are in hurry to start the cutting an order and start cutting without checking pre-requisites for cutting process, you might fall into the trap. Having fabric in store is not enough to go for bulk cutting. You must have approvals on few important things prior to layering the fabric on the cutting table and cutting the lay. If you cut fabric without approvals and unfortunately if something goes wrong in production (or shipment) due to cutting mistakes you will be responsible for that. Other than that if fabric is not approved or if you use incorrect patterns for the bulk cutting, cuttings can’t be used for stitching quality garment. PP sample approval and PP meeting is must be done prior to bulk cutting.

To avoid the risk of making mistakes in bulk production you must consider checking following things.

What is Pilot Run in Garment Manufacturing?

Pilot run can be named as trial production run. Pilot run is done after approval of PP sample and before bulk cutting. Pilot run for a style (order) is conducted if buyer asked for it. Many garment manufacturers set pilot-run as standard procedure. In those companies Pilot run is must for all styles irrespective of buyer requirement.

Garment manufacturer cut around 100-200 garments per style for the pilot run. This production is done based on PP comments. All 200 pieces are treated as mini production. Factory follows complete processes planned for the order. Factory sets up stitching line. And production for the pilot run is done as it to be done for the bulk production.

Production Planning and Control – the Concept and Definition

This is a guest post from Ashish Kumar Gupta.

Production Planning is one of the integral parts of any manufacturing unit. The process complexities vary in degree depending upon the number of processes involved in the production of desired product. With the globalization the sourcing process has become complex as international boundaries are not a deterrent in conducting the business.

Production planning is a managerial function mainly concerned with the following issues.

International GOTS Conference in India (May 22, 2015)

The First International GOTS Conference-‘Strong Partnerships for Success’, to be held on
May 22, 2015, in Mumbai, India.

India is the largest producer of organic cotton (around 70 per cent of the world). It is also the largest processing and export market of textiles using organic fibres. With more than 1,000 facilities, India is also the country with the highest number of GOTS certified facilities worldwide, which makes it actually the hottest sourcing destination for the same. However, even more commitment is required at garmenting stage to further exploit the potential in this sector.

Common Practices Followed to Control Fabric Shrinkage in Garment Manufacturing

Fabric shrinks when it is washed. This is one of the common facts of fabric quality. How much fabric will shrink is not predictable. As fabric shrinkage varies from one type of fabric to another. Even roll to roll shrinkage variation is found for the same fabric and in the same order (due to lot variation). Woven fabric shrinkage (2-4%) will vary from knits shrinkage (3-8%). Shrinkage of stretchable fabric (10-18%) is higher compared to normal woven fabrics.

In this article I will share common practices followed by garment manufacturers to control fabric shrinkage in fabric as well as in garment. To control fabric shrinkage to wash you first need to test fabrics prior to taking any action. Common processes of measuring fabric shrinkage are discussed here.

Use Pivot Table and Become Smart in Report Making (Download Excel Template)

Report making is one of the daily activities for most of the garment manufacturers in the garment industry. Most of the them use spread sheet (MS Excel or Open Office) for making daily production report and other reports.

I assume that you are one of them. You may know how to use spread sheet. The question is how are you utilizing excel tools to make your reports?

What is Inline Inspection in the Garment Industry?

Inspection means checking the quality of a work or a product. Inline Inspection means checking quality of the product in the process instead of checking at the end of the process when product is completely made. Inline inspection in a garment factory means checking of semi-stitched garments or partially stitched garments while pieces are still inside the line and all sewing operations are not yet stitched.

Inline inspection is also known as roving quality checking or roaming quality checking. Inline inspection is done for 100% of garments or certain percentage of total stitched pieces. Various format of inline checking exits in the garment stitching.

4 Point System for Fabric Inspection: A Discussion Post

I guess you completely understand the use of 4 Point System and method of measuring total penalty points per 100 square yards. If you have any doubt and have questions read this post thoroughly and comment on it.

Last month I have received one mail with so many questions and queries on 4 Point systems. When I first time wrote an article on 4 Point System, I did not thought that much dip. 

This is a real life case. I have received this issue with some queries and replied him back with appropriate answers. I am not sharing the name of the sender of this mail. 

What is Bundle Allowance?


You may already know that to determine Standard Time (SAM) using Time Study method various allowances are added to the basic time. Bundle allowance is one such allowance. Do you know what bundle allowance is?

In Progressive Bundle Production System (PBS), number of garments are bundled together. These bundles are fed to the sewing line. Sewing operators need to open (untie) the bundle before he can start sewing garment pieces. After completing one bundle operators need to tie up the bundle before he stacks the bundle or slide it to the following operator. For this activity operator spends certain time. It may be fraction of minutes. The time required for bundle tying and untying is considered as bundle allowance.

How to Produce Accurate Standard Times?

This is a guest submission from Sunaina Khanna

Some times ago we had the opportunity to build a system to establish standard times for the garment industry, this was caused by the continued problem of poor production planning, and not knowing how well the company was performing, how efficiently we performed the various operations, and what our status was in comparison to our competitors.

We needed something that was easy to use, simple, and of course would produce accurate standard times. It had to be able to produce the best possible method of doing the operation and allow performance to be measured to see where we stood in comparison to the rest of the industry.