martes, 18 de octubre de 2016

By SAP Business One / Apparel & Footwear Solution
It is a long journey of garments before they are put on display in a store. Since raw material purchase to reaching to retails shop may takes 30-100 days. 
These are some of the steps explaining how our garments are made in factories and shipped to the retailers.

    Garment Design

A designer first makes the garment design on paper or using a CAD tool – such as Illustrator. The file then is uploaded to a common repository.

Designers usually create styles in CAD design software and upload to SAP B1 – AFS solution.

Styles are categorized and managed in the same database

      Garment sampling and product development

And at the development stage design concept is converted into garment using fabric and trims. Sampling is making the proto type of the final garment. Brands spend lot of time and resources on product development. They also work on developing fabrics, if they wish to use a new kind fabric for their designs. Different types of samples are made for different purposes. Samples made by a factory may include proto sample, size set sample, salesman sample and pre-production sample etc.

All data is available in the Product Data Management (PDM) to manufacture and delivery the style.

     Garment pattern making

When we buy readymade garments we choose the garment that fits better to our body. A garment is made by joining various garment components together. Like a shirt has parts like collar, cuff, sleeve, front panels, back panel, back yoke and front plackets. Do you know that a full sleeve shirt is made of about 20+ different components? To get correct garment fitting, all garment parts are cut following the specific dimension (measurements). For this we need garment patterns. Factories make garment patterns manually as well as by CAD software. Then each pattern is linked to a material in the cost sheet, starting point of the Bill of Material.

Sourcing of fabrics, trims and packing accessories

You might know that fabric is the primary raw material for making garments. To make a garment we need various kinds of trims too depending on garment design. Common trims are like stitching threads, buttons, zippers, twill tape, laces, hook, snap buttons etc. Factory sources fabrics and all other items from the local market or from the buyer nominated suppliers. Prior to use these items, factory checks quantity and quality of the items.

During product development the cost sheet calculates the planned fabrics , trims and operations. Then all materials based on garment attributes are lined to each sku and BOM

     Cutting garment parts

As mentioned above, to make a garment factory cuts fabrics into garment parts. In mass garment production numbers of garments are made for the same design and same size. Multiple fabric plies are cut together after layering fabrics on the cutting table. After fabric layering, marker is made manually on the top ply using pattern paper or CAD generated maker sheet is laid on the top layer. A trained cutter cuts fabric following pattern outlines by means of cutting equipment.

Manufacturing order is created with the garment routing. All jobs are tracked

 Printing and Embroidery

You might have seen printed designs or/and embroidery designs on your clothes. Printing and embroidery work are value added but optional process. All designs may not have print and embroider work. Printing or Embroidery is only done if customer asked for it. Printing on garments is done either on full length fabric or on garment panels after cutting garment components.

     Garment Stitching

You might have seen tailors to stitch garments in a tailoring shop. They normally use 2-3 types of sewing machines and one person makes the whole garment. In industrial production things are different.

Cut components are taken into sewing section. Garments are stitched in assembly lines. Large numbers of stitching machines are installed in multiple sewing lines in the stitching floor. Stitching operators stitch garment parts together and assemble garments. One operator sews only one or couple of operations. Hence numbers of operators are involved in completing the stitching of a garment. 

Just stitching garment parts are not enough. All garments must be defect free. To ensure stitching quality factory involves quality checkers to check the stitched garments in the line and end of the line. All defective garments are repaired in the line prior to sending garment to the next process. 

      Garment washing

Being a customer we would never buy a soiled or stained garment. Brands know this. So factory takes care of garment presentation and finishing. Factory cleans all oil stains, pencil/chalk marks, dust by spotting or washing. Garment washing is done to remove dirt and dust from the garments. 

     Finishing of stitched garments

A stitched garment comes with lot of loose threads, long thread tails, numbering stickers, various kinds of stitching defects, raw material defects and handling defects. In finishing section thread trimming, sticker removing and spot removing are done. 

Garment folding and packing

Nicely pressed garments are folded in a specific dimension. All garment accessories and tags like hang tags and price tags are attached to each garment. Folded garments are then packed into poly bags. Packing is done for individual garments or multiple garments are packed into a poly bag. Barcode stickers are attached to the price tags. Then garments are packed into a bigger carton.

     Garment Inspection and quality assurance:

We have learned that garments are checked at stitching and finishing stages. At this stage finished and folded garments are audited for quality assurance of the products. Factory follows certain quality standard, and inspection procedure to audit the packed garments. 

     Shipment delivery

Passed shipments are sent to buyers/retailers. For domestic order finished garments are sent to retailers’ warehouse or directly to the distribution centers. Thus our favorite clothes reach to retails stores. 

From design to delivery and invoice. SAP Business One and the AFS solution allows companies to manage the entire process with one powerful solution. 

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