Apparel Production

Experts and garment industrialist still showcase Indian apparel industry as an unorganised sector to the world. As because many factories don't yet measure their performance level in terms of operational efficiency and other major KPIs.

 Apparel Manufacturing - an overview 
Apparel production, also known as garment production is a process where fabric is being converted into garments. The term apparel production is basically used when garments are manufactured in a factory. Traditionally apparel manufacturing factories has been divided into two sectors as domestic and export.

Which payment system is better for sewing operators in garment manufacturing - Piece rate or Salary based?
When entrepreneurs start business in garment manufacturing and garment exports, they look for a fair payment system that would motivate their workers as well as factory can save good money out of the business. Whether payment system is salary based, piece rate or incentive system.

Cutting room overview
Garment production starts with the cutting process. In this process, fabric is being cut into components (shapes or patterns of different garment parts, i.e. front, back, sleeve, collar shapes etc.). In mass production multiple layers of fabrics are laid on a table and large number of garments is being cut at a time.

Cutting room terminology 

How to determine fabric utilization% in cutting room?
Fabric utilization means how much fabric is being utilized in cutting for garment patterns out of total fabric laid for cutting. Generally, fabric constitutes 60% to 70% of the total garment cost. So, through effective fabric utilization factory can save lot of money from fabric.

Comparison between progressive bundle system and UPS system 
In the industrial sewing plants various types of sewing systems are installed. A plant owner chooses these systems depending on the production volume, product categories, and cost effectiveness of high tech machineries. Among those “Progressive Bundle System” (PBS) is mostly installed sewing system till date.

How to estimate garment production 
It is a very important question, because it is the basic knowledge about production management and each people who are working in production must know how estimated production is calculated.

How to measure labour productivity?
Most simply, productivity is the ratio between output and inputs.

Garment Production Systems
In simple a ‘garment production system’ is a way how fabric is being converted into garment in a manufacturing system. Production systems are named according to the various factors, like- Number of machine are used to make a garment, Machines layout, Total number of operators or tailors involved to sew a complete garment and Number of pieces moving in a line during making a garment.

Difficulties in managing smaller garment export orders
Those days have gone when factories had only two seasons in a year and were getting bulk order quantity with few styles and with 90 t0 120 days lead time. As per some factory owners, the behaviour of the market is not just quality and time driven but other factors too affect it.

How to stop missing of garments in production processes?
Most of the garment export house has a common story at the time of shipment offering. Buyer quality inspector waits at quality inspection room for full shipment offer. People in the finishing and packing department try hard to complete finishing and packing full order. Few people are busy in counting total packed pieces and to be packed pieces. But their count doesn’t match with total cut quantity.

Pre-production processes in garment manufacturing
The processes that are done prior to start of bulk garment production are known as pre-production process. From sample development, approvals, research and development work for orders, testing of raw material to pre-production meeting are pre-production process. Pre-production processes are very important for the efficient production.

Machines used for Denim (Jeans) Manufacturing
Denim is known as all time fashion for all age group and for both sex. The demand of denim pants are always there. To supply enough Jeans to the sourcing countries entrepreneurs are setting plants in low labor cost countries.

Garment Washing - an important process in garment production
Garment washing is normally processed after stitching. As per fashion trend and customer demand buyers ask for garment washing though it increases the cost of the garment. For the washing they mention exactly what types of washing they need for the order. For example, Tom Tailor buyer asked for washes like – Vintage wash, Cloud wash, softener wash or Acid wash.
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