Showing posts from November, 2014

How to Get into Garment Business?

I had received hundreds of queries related to small business set-up in the garment industry. Most of them expressed their desire to learn - how to get into garment business? What are the requirements for setting up a business? How much money need to invest in the project? Etc.

In this post, I will show you things that you need to look into for starting a small-scale business in garment manufacturing.

Remember, it is not necessary to learn everything about garment manufacturing. Just learn what all areas you need to focus and how to get into this business step by step. For other things, you can employ skilled professionals and experts. Also, remember by reading this small piece of article, you are not becoming an expert in stating garment business, but you will get direction for your plan of actions.

Following are the key steps to get into garment manufacturing business.

Select a product range. There are many product categories in the clothing line. Prior to entering into business and w…

Frequently Asked Questions on Garment Business Start-up

I know you have many questions that need to be answered. I have published this page - 'Frequently Asked Questions on garment business start-up' to answer questions those I receive frequently.

Read the following titles and click on it for the answer. I am building this page and will be adding more FAQs soon. In case, your question is not answered here, please write to me using the contact form.

If you like to add something to my answer, please add your comments in the following comment box. Or send me mail mentioning question. I will add your points here.

1. I want to start a small business in the garment Industry. What would be a suitable business for me?
In the article '10 small business ideas in garment industry' I have listed business ideas. Read this article, if you have not yet read it. Similar businesses can be started in a bigger scale. Selecting the right business for you depends on various things. In what kind of business you feel comfortable. It is not possibl…

Readymade Garment Business – The Manufacturing Process Checklist

How to execute readymade garment orders? What would be the checklist for processing an order without much problems in the internal processes? - These are the common questions asked by start-up entrepreneurs and small garment business owners.

It is very important that every manufacturers should follow standard procedures for making readymade garments. This article covers such standard procedures in brief. To take your business process into the next level read following checklist and follow it.

Considering that you have received an order (shirt order) for manufacturing. And your goal is to deliver the order on time with full quantity and with best possible quality.

Followings are steps must be followed during processing an order.

10 Steps for Effective Implementation of 5S

This is a guest submission by Manoj Singh.

5S is considered as foundation and gateway of all kind of improvements. Successfully implemented 5S gives amazing results through employee workplace discipline. Remember, serious commitment from top management is required for successful implementation of 5S.

In this article, Manoj has explained how you can implement 5S effectively in 10 steps.

You might be knowing what 5S is. If not see the definition of 5S in the following box.

5S (FIVE S) Sort: Remove unwanted item from workplace and dispose them properlySet in order: Arrange every item as per its usage frequency making it easily available for use - “A place for everything and everything in its place”Shine: Clean the workplace and look for the source, which is adding dirty substance and work towards eliminating that sourceStandardize: Everything in right order as per set standards, with high standard of housekeeping. Each workplace should have proper layout displaySustain: Properly train…

Apparel Merchandising - Roles and Responsibilities

Apparel merchandising is one common job profile in the apparel supply chain. Merchandisers are found working with a buyer, in buying offices, in export houses and in fabricator’s workshop. Even in the same organization merchandisers may play different roles depending on their job profile.

Merchandising department works as a mediator in between factory and buyers. This department is considered as heart and soul of the company. They coordinate with buyers for order, send a sample for approvals and receive comments on samples and other approvals. Merchandiser prepares the bill of materials (BOM), garment costing sheet and follows up with production processes. 
In this small piece of article, job responsibilities of an export house merchandiser are explained.

Roles and Responsibilities of Apparel Merchandisers
1. Communicating with buyers: Merchandisers communicate with the buyer on regular basis to understand buyer’s needs. They communicate with the buyer for clarifying each and every qu…

T-Shirt Design: Best Possible Ways to add Your Brand Label and Brand logo in a T-Shirt

Selecting the right place for attaching a brand label or brand logo on a T-shirt is a part of T-shirt designing. There is a number of options. I will be sharing different ways of attaching your brand logo and a brand label on a T-shirt.

I was preparing Garment Techpack for the premium quality T-shirts. I was trying to make it informative with all the technical details. The purpose was to provide every detailing of the t-shirt construction to suppliers through the teckpack and minimize to and fro communication between supplier and buyer.

In this process I did a short research and reviewed many premium quality t-shirts, sport wears (T-shirts), and polo shirts to understand variation in construction details and design features.

One thing I found very interesting that brands are very innovative in labelling and selecting a place in the garment for the brand label or brand logo. It is not just building a brand but also make the T-shirt awesome.

I learned label can be attached to a T-shi…

4 Point Inspection System: Acceptable level (Points per 100 square yards)

4 Point Inspection System is the most common and widely used fabric quality inspection system for all types of fabrics in the textile and apparel industry.

4 Point inspection procedure for fabrics, criteria for giving penalty points for fabric defects and calculation method of total points in an inspected fabric roll is explained in this article. (If don't know basics of 4 point inspection system, I would suggest you read that article first.)

How T-Shirts are made in Garment Factories?

The T-shirts displayed in retail stores might be sourced from a different part of the world. If you shop a Crew Neck Tee from a shop in New York City, that piece might be sourced from one of the Asian countries. There are big factories (small as well) where these T-shirts are made. And sourced by brands or retailers. Did you ever try to know how t-shirts are made?

In a garment factory, hundreds of T-shirts are made daily. A garment factory gets the order for making T-shirts from international buyers or brands. It performs a number of activities to make finished T-shirts. In this post, you will be shown various processes a T-shirt factory follows up to shipping of T-shirts to its buyer.

14 Websites to Create Custom Printed T-Shirts (E-Commerce Site)

Are you looking for custom printed T-shirts? Or Do you like to wear a Tee that has your favorite quote? Don't worry. There are many websites from where you can order Tees with custom print. Like apparel e-commerce stores, online custom printed T-shirt stores are also grooming and you have many options.

More than just individual needs, custom print T-shirt are available for a group of people, promotional T-shirt, School uniforms, corporate uniforms and campaign.
Few of the following sites include products such as Polo Shirt and Jackets for custom print apparel. Other sites provide service for many product categories and T-shirt design is one of them. There are many international websites those provide custom print T-shirt design. This list includes only Indian websites though many of them sells their T-shirt to international customers.

Process of Sweater Manufacturing

We all know what a sweater is. But do you know - how sweaters are made in factories? Let me explain how sweaters are made through various processes. One more thing I like to share with you that I have worked in a sweater manufacturing company in Dhaka, Bangladesh for two months in 2006. I remember how we worked in that factory.

Sample development, sample approvals and order receiving process are similar to garment manufacturing. Other processes are explained here in brief.

1. Yarn sourcing - Yarns are a primary raw material for sweater knitting. Factory sources yarn in hank or spool form. The factory I worked had their own spinning mill and yarn dyeing unit.

2. Winding of yarns - In this process, yarns are winded into cones from hanks in the winding machine. These cones are stored for production.

3. Yarn issue to production - Yarn distributor is employed for distributing yarn cones to operators. Yarn distributor collects yarns from a yarn store as per the order plan. Yarns cones …

How Socks are Made? (Video)

Did you ever see sock making in a factory or watch any video?  Here I am sharing some cool videos of socks manufacturing.

I am not an expert in sock manufacturing. The fact is that I didn't know how a pair of socks are made in a machine. Today I found a couple of good videos on YouTube that shows various processes of sock manufacturing and the last video explains major processes.

Like me, if you are also interested to know how socks are made in a factory, watch following videos.

How to Use Performance Rating Calculating BasicTime?

In the article Calculation of SAM using Time Study I have used operator performance rating to calculate basic time. Many readers asked me a question on basic time calculation using performance rating. I understand that basic time calculation method has not been clearly explained in the earlier post. I thought to clarify this question to OCS readers in this post.

Two recent questions are published here (name of the question sender is changed).

Question#1:In your article, you indicate that if an operator has an 80% rating that you multiply the cycle time by the rating (which reduces the cycle time for the operation). Wouldn't you actually divide the cycle time by the rating to INCREASE the cycle time for the operation before you add the other allowances? ... asked by Rick

What is Balancing Loss in Garment Production?

Prior to loading production to the line (for a new style), Industrial Engineers prepare an operation bulletin (OB) for the style. In the operation bulletin, IE plans calculated manpower and machine requirement based on SAM of all operations (pitch time) and production target per hour (or per day). This is known as calculated (or theoretical) machine requirement. In the calculated machine numbers, a fraction of machine number may come but practically fraction of machine cannot be set in the sewing line.

In the operation bulletin, IE also plans the actual machine requirement for each operation. See the following image. Where possible, operations are clubbed (where similar machine type is required) for balancing available time per machine and SAM of operations. But for all operations balancing is not possible. That is why in the OB, IE gets variation in between two figures - calculated machines and actual machine numbers. Total variation of the machine numbers for a style is known as b…

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