SAMPLING

Sampling is the process by which factories create garment samples based on the buyer's specified design. This is also known as the product development phase. Samples are required at various stages to obtain buyer approval on a specific design. Samples are categorized as Proto sample, Fit sample, Size set sample, Salesman sample, production sample, Top of production (TOP) sample, and shipment sample based on their development stage.

COSTING

A business is all about profit. So accurate product costing before order finalization is critical. The cost of a garment is the total cost of raw materials, direct labor, and direct and indirect overheads. After developing a sample or directly receiving a buyer's sample, the factory must send the FOB (freight on board) price of the garment. To determine FOB, a garment factory creates a cost sheet that includes raw material costs, total direct labor costs for each process, and factory overhead. A FOB is the total of the garment cost, factory margin, and taxes.

PRE-PRODUCTION PLANNING

After receiving the order, the factory plans the raw material requirements for the order. Raw materials include fabrics, sewing threads, packing supplies, hang tags, and other accessories. The factory plans timelines such as when to begin cutting when to submit pre-production samples, when to complete sewing and finishing, the final inspection date, and the shipment date. In the production planning stage, job responsibilities for various processes are defined.

PRODUCTION

In the sewing room, garment panels are stitched together using sewing machines. Sewing involves converting 2D fabric patterns into 3D forms. An operator runs the machine, and garment parts are joined together with sewing threads. Sewing machines come in a variety of types. The machines are chosen based on the seam and stitch requirements. Traditionally, sewing machines are laid in a raw state. Cut parts are fed at the beginning of the line, and passed through it, and a complete garment is produced at the end. Individual operators run each machine, and each operator sews only one or two garment operations. A line is made up of sewing operators, a helper who feeds them cut parts and thread.

FINISHING

In general, this process consists of garment checking, measurement checking, ironing, and spotting. After the garments are sewn, a quality checker inspects each piece to ensure that they meet the buyer's quality standards. Checking is usually done for visual appearance and measurements. Spotting is required to remove the stain in the pieces. To remove oil stains, marks, and hard stains, a variety of chemicals (solvents) are used. The garments were then ironed to remove creases using a press.

THE FINAL INSPECTION AND DISPATCH

The buyer quality assurance (QA) department inspects the garments after they have been packed (also known as shipped) but before they are dispatched. Often, a third-party quality auditor is hired for this final inspection. If the packed goods meet the buyer's quality standards, the buyer accepts the shipment. The factory then delivers the goods to the buyer.

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