Manufacturing Sequence of Manufacturing Sequence of GarmentsGarmentsOperation

Idea Generation

Grading

Production Pattern

Sample Making

Pattern Design

Design/Sketch

Fabric Spreading

Marker Making

Lay Planning

Cutting

Numbering

sewing

Printing/Embroidery/Interlining

Washing/DyeingFinishing

Packing Final Inspection

Delivery

Idea GenerationIdea Generation►► The process by which new The process by which new

DESIGNS DESIGNS are are deliberately produceddeliberately produced►► Fashion designers are Fashion designers are assigned for this assigned for this processprocess► ► Idea generation Trip to Idea generation Trip to get ideaget idea►► Idea about Color received Idea about Color received from Color from Color forecasting forecasting magazines like ColorTrends, magazines like ColorTrends,

Color Decoder etc. Color Decoder etc. ►► Spring/Summer Spring/Summer forecasted color: Coralforecasted color: Coral

Idea GenerationIdea Generation

Idea GenerationIdea Generation

Idea GenerationIdea Generation

SketchSketch

Sketch of a particular garment Sketch of a particular garment including its design features is including its design features is essential on paperessential on paper

Sample garment are Sample garment are produced and verified with its produced and verified with its sketchsketch

Could be done manually or Could be done manually or with the software, popular with the software, popular software is kaledo style of software is kaledo style of LectraLectra

SketchSketch

SketchSketch

SketchSketch

Pattern designPattern design

Hard paper copy of each Hard paper copy of each component of a garment of component of a garment of exact size and shapeexact size and shape

Pattern also include seam Pattern also include seam allowance, shrinkage of the allowance, shrinkage of the fabric trimming allowance, fabric trimming allowance, dart etcdart etc

Could be done manually or Could be done manually or with the help of a computerwith the help of a computer

Pattern DesignPattern Design

Sample MakingSample Making

Patterns are used to cut fabricPatterns are used to cut fabric

Cut components are Cut components are assembled to make a sample assembled to make a sample garmentgarment

Usually done by a very Usually done by a very efficient and technically sound efficient and technically sound personperson

Sample Garment Sample Garment

Sample GarmentSample Garment

Production PatternProduction Pattern

Pattern of the approved Pattern of the approved sample garments are used to sample garments are used to make production patternmake production pattern

Minor modification may done Minor modification may done on production pattern if buyer on production pattern if buyer have any advice. have any advice.

GraddingGradding

Stepwise increase or Stepwise increase or decrease of a master patterndecrease of a master pattern

To get the pattern of all size To get the pattern of all size from a master patternfrom a master pattern

Could be done manually or Could be done manually or with the help of softwarewith the help of software

GraddingGradding

Gradded patternGradded pattern

Lay PlanningLay Planning

Marker MakingMarker Making

All the pattern pieces for the All the pattern pieces for the required sizes are arranged in required sizes are arranged in the paper in such a way so the paper in such a way so that required number of that required number of different size garments may different size garments may be produced with minimum be produced with minimum fabric wastagefabric wastage

Used for calculation of exact Used for calculation of exact consumption of fabricconsumption of fabric

Could be done manually and Could be done manually and with the help of computer with the help of computer

Marker MakingMarker Making

MarkerMarker

SpreadingSpreading

Process of arranging fabric on Process of arranging fabric on the cutting table to cut the cutting table to cut

Height of the lay is limited up Height of the lay is limited up to maximum six inchto maximum six inch

Could be done manually or Could be done manually or mechanicallymechanically

SpreadingSpreading

SpreadingSpreading

CuttingCutting

Normally straight knife cutting Normally straight knife cutting machine is used to cut out the machine is used to cut out the garment component as per garment component as per exact dimension of the patternexact dimension of the pattern

Care must be taken to avoid Care must be taken to avoid cutting defectscutting defects

CuttingCutting

Cutting (Auto)Cutting (Auto)

Numbering and Numbering and bundlingbundling

Printing and Printing and embroideryembroidery

These two process are done These two process are done before sewingbefore sewing

Both printing and embroidery Both printing and embroidery requires flat form of the fabric requires flat form of the fabric for processingfor processing

Printing, Embroidery, Printing, Embroidery,

InterliningInterlining

Printing and Emb.Printing and Emb.

SewingSewing

Cut pieces of fabric is Cut pieces of fabric is assembled in this processassembled in this process

Most important section of Most important section of garment manufacturing unitgarment manufacturing unit

Vertical line balancing is done Vertical line balancing is done to produce a specific garmentto produce a specific garment

Numbers of sewing machine Numbers of sewing machine per line varies from 15 to 60 per line varies from 15 to 60 depending on style of the depending on style of the garmentgarment

AssemblingAssembling

FinishingFinishing

After passing through After passing through inspection table, all garments inspection table, all garments are normally go through are normally go through thread sucking machine to thread sucking machine to remove floating dirt, remove floating dirt, measured and ironed/pressed measured and ironed/pressed to remove unwanted crease to remove unwanted crease and to improve smoothnessand to improve smoothness

Thread suckerThread sucker

FinishingFinishing

FinishingFinishing

FinishingFinishing

finishingfinishing

PackingPacking

Finished garments are folded Finished garments are folded as per buyers instruction, as per buyers instruction, inserted into the poly bags inserted into the poly bags and cartooned as advised by and cartooned as advised by the buyerthe buyer

PackingPacking

Inspection (Final)Inspection (Final)

Final random inspection (FRI) is Final random inspection (FRI) is usually done by the buyer or the usually done by the buyer or the representative of buyerrepresentative of buyerAfter completion of packing FRI is After completion of packing FRI is conductedconductedAQL is applied in FRI as advised AQL is applied in FRI as advised by the buyerby the buyerUsually AQL 2.5 is applied in Usually AQL 2.5 is applied in Apparel inspectionApparel inspectionGoods are delivered to the Goods are delivered to the shipping agents if goods are shipping agents if goods are passed in the FRI passed in the FRI Goods are sent to the finishing Goods are sent to the finishing section for repair/amend if goods section for repair/amend if goods are failed in the FRIare failed in the FRI

Final inspectionFinal inspection