PP meeting
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. A typical garment export house generally has following pre-production processes:
In this stage designer of a manufacturing house shows their creations, latest designs to buyers. On other hand if buyer already had fixed design of a style and need few changes on it related to fit, fabrics or trims they discuss those thing with the merchandiser of the manufacturing unit.
Development of initial samples for the buyer
In this stage after receiving buyer’s concept or instructions on the new style, samples are made with available fabrics and trims
Development of fabric sample, bit loom, print and embroidery artwork
Fabric is developed as per the buyer requirement. Fabric development means sourcing of customer specific fabric with matching properties, dyed and finished for solid colors. For the solid color lap dip approval is very important process. Until lap dip sample is approved merchants re-submit lap dips. In case of yarn dyed fabrics merchants develop fabric sample with specified design, stripes or checks. These fabric samples called as Bit Loom. Other approvals such as print and embroidery artwork approval and color approval are done. It may be done later stage at time of pre-production.
Costing of garment (complete cost as well as manufacturing cost)
Merchants prepare cost sheet with details cost break up such as raw material cost, manufacturing cost, overheads and margin. Costing is very a critical stage. Because whether a company will get order or not depends on their costing. If they garment cost is very high then manufacturer may lose the order and on other hand if factory keep their cost low, they will not earn profit from the order. Estimation of the garment cost should be done on data based.
Pattern making, correction of pattern, pattern grading
Pattern master prepares first fit pattern, then re-develop pattern adding buyer comments and rectification on fit sample. After fit approval pattern master grade pattern for size set samples only for specified sizes. Once order is ready for production they grade pattern for whole size range.
Fit sample, size set sample making and approval from buyer
Each sample has certain purpose. Samples are made in sampling department and sent to buyer for approvals.
Correction of fit samples according to buyer comments
If sample is not approved or further work is recommended by buyer. Correction is done and re-submitted to buyer.
Approval of fabric swatches, print colors, embroidery design, bead works
Production planning, Material planning and line planning
To start production on time and ship the order on time planning is must. Planning is needed for material sourcing, production capacity, line planning. Scheduling of jobs and responsibility is defined at this stage.
Placing order for fabrics, trims, accessories and packing materials
Sourcing of raw material.
Testing of fabrics and other raw materials
Physical properties are being tested for bulk fabric. This test can be done in in-house testing labs.
Study of approved sample
For operation break down, work content, critical operation and line setting. Also finding best ways for producing the garment most efficiently in the production stage.