apparel manufacturing

1. Manufacturing Sequence ofManufacturing Sequence of
GarmentsGarments
Operation
Idea Generation
Grading
Production Pattern
Sample Making
Pattern Design
Design/Sketch
Fabric Spreading
Marker Making
Lay Planning
Cutting
Numbering
sewing
Printing/Embroidery/Interlining
Washing/Dyeing
Finishing
Packing Final Inspection
Delivery

2. Idea GenerationIdea Generation
►► The process by which newThe process by which new
DESIGNSDESIGNS areare
deliberately produceddeliberately produced
►► Fashion designers areFashion designers are
assigned for thisassigned for this processprocess
►► Idea generation Trip to getIdea generation Trip to get
ideaidea
►► Idea about Color receivedIdea about Color received
from Colorfrom Color forecastingforecasting
magazines like ColorTrends,magazines like ColorTrends,
Color Decoder etc.Color Decoder etc.
►► Spring/Summer forecastedSpring/Summer forecasted
color: Coralcolor: Coral

3. Idea GenerationIdea Generation

4. Idea GenerationIdea Generation

5. Idea GenerationIdea Generation

6. SketchSketch
Sketch of a particular garmentSketch of a particular garment
including its design features isincluding its design features is
essential on paperessential on paper
Sample garment areSample garment are
produced and verified with itsproduced and verified with its
sketchsketch
Could be done manually orCould be done manually or
with the software, popularwith the software, popular
software is kaledo style ofsoftware is kaledo style of
LectraLectra

7. SketchSketch

8. SketchSketch

9. SketchSketch

10. Pattern designPattern design
Hard paper copy of eachHard paper copy of each
component of a garment ofcomponent of a garment of
exact size and shapeexact size and shape
Pattern also include seamPattern also include seam
allowance, shrinkage of theallowance, shrinkage of the
fabric trimming allowance,fabric trimming allowance,
dart etcdart etc
Could be done manually orCould be done manually or
with the help of a computerwith the help of a computer

11. Pattern DesignPattern Design

12. Sample MakingSample Making
Patterns are used to cut fabricPatterns are used to cut fabric
Cut components areCut components are
assembled to make a sampleassembled to make a sample
garmentgarment
Usually done by a veryUsually done by a very
efficient and technically soundefficient and technically sound
personperson

13. Sample GarmentSample Garment

14. Sample GarmentSample Garment

15. Production PatternProduction Pattern
Pattern of the approvedPattern of the approved
sample garments are used tosample garments are used to
make production patternmake production pattern
Minor modification may doneMinor modification may done
on production pattern if buyeron production pattern if buyer
have any advice.have any advice.

16. GraddingGradding
Stepwise increase orStepwise increase or
decrease of a master patterndecrease of a master pattern
To get the pattern of all sizeTo get the pattern of all size
from a master patternfrom a master pattern
Could be done manually orCould be done manually or
with the help of softwarewith the help of software

17. GraddingGradding

18. Gradded patternGradded pattern

19. Lay PlanningLay Planning

20. Marker MakingMarker Making
All the pattern pieces for theAll the pattern pieces for the
required sizes are arranged inrequired sizes are arranged in
the paper in such a way sothe paper in such a way so
that required number ofthat required number of
different size garments maydifferent size garments may
be produced with minimumbe produced with minimum
fabric wastagefabric wastage
Used for calculation of exactUsed for calculation of exact
consumption of fabricconsumption of fabric
Could be done manually andCould be done manually and
with the help of computerwith the help of computer

21. Marker MakingMarker Making

22. MarkerMarker

23. SpreadingSpreading
Process of arranging fabric onProcess of arranging fabric on
the cutting table to cutthe cutting table to cut
Height of the lay is limited upHeight of the lay is limited up
to maximum six inchto maximum six inch
Could be done manually orCould be done manually or
mechanicallymechanically

24. SpreadingSpreading

25. SpreadingSpreading

26. CuttingCutting
Normally straight knife cuttingNormally straight knife cutting
machine is used to cut out themachine is used to cut out the
garment component as pergarment component as per
exact dimension of the patternexact dimension of the pattern
Care must be taken to avoidCare must be taken to avoid
cutting defectscutting defects

27. CuttingCutting

28. Cutting (Auto)Cutting (Auto)

29. Numbering andNumbering and
bundlingbundling

30. Printing andPrinting and
embroideryembroidery
These two process are doneThese two process are done
before sewingbefore sewing
Both printing and embroideryBoth printing and embroidery
requires flat form of the fabricrequires flat form of the fabric
for processingfor processing

31. Printing, Embroidery,Printing, Embroidery,
InterliningInterlining

32. Printing and Emb.Printing and Emb.

33. SewingSewing
Cut pieces of fabric isCut pieces of fabric is
assembled in this processassembled in this process
Most important section ofMost important section of
garment manufacturing unitgarment manufacturing unit
Vertical line balancing is doneVertical line balancing is done
to produce a specific garmentto produce a specific garment
Numbers of sewing machineNumbers of sewing machine
per line varies from 15 to 60per line varies from 15 to 60
depending on style of thedepending on style of the
garmentgarment

34. AssemblingAssembling

35. FinishingFinishing
After passing throughAfter passing through
inspection table, all garmentsinspection table, all garments
are normally go throughare normally go through
thread sucking machine tothread sucking machine to
remove floating dirt,remove floating dirt,
measured and ironed/pressedmeasured and ironed/pressed
to remove unwanted creaseto remove unwanted crease
and to improve smoothnessand to improve smoothness

36. Thread suckerThread sucker

37. FinishingFinishing

38. FinishingFinishing

39. FinishingFinishing

40. finishingfinishing

41. PackingPacking
Finished garments are foldedFinished garments are folded
as per buyers instruction,as per buyers instruction,
inserted into the poly bagsinserted into the poly bags
and cartooned as advised byand cartooned as advised by
the buyerthe buyer

42. PackingPacking

43. Inspection (Final)Inspection (Final)
Final random inspection (FRI) isFinal random inspection (FRI) is
usually done by the buyer or theusually done by the buyer or the
representative of buyerrepresentative of buyer
After completion of packing FRI isAfter completion of packing FRI is
conductedconducted
AQL is applied in FRI as advisedAQL is applied in FRI as advised
by the buyerby the buyer
Usually AQL 2.5 is applied inUsually AQL 2.5 is applied in
Apparel inspectionApparel inspection
Goods are delivered to theGoods are delivered to the
shipping agents if goods areshipping agents if goods are
passed in the FRIpassed in the FRI
Goods are sent to the finishingGoods are sent to the finishing
section for repair/amend if goodssection for repair/amend if goods
are failed in the FRIare failed in the FRI

44. Final inspectionFinal inspection