Gini Frings Upper Saddle River, New Jersey 07458 Patternmaking • Accurate patternmaking is crucial for successful apparel production. • Most large manufacturers make patterns on a computer using Computer Aided Design, or CAD. • Grading is the method to increase or decrease the sample size production pattern to make a complete size range. • Markers are the cutting guide on a sheet of lightweight paper the same width as the fabric.
Gini Frings Upper Saddle River, New Jersey 07458 Production Scheduling • Contractors schedule production and garment assembly in time to met shipping dates. • The production schedule, or issue plan is a reverse timetable usually covering six months. • The first date is a shipping date that meets the retailers order requirements. • Plant capacity must be considered in planning the production schedule. • Computerized inventory control has made planning more accurate.
Gini Frings Upper Saddle River, New Jersey 07458 Spreading and Cutting Procedures • After the issue plan, a cutting order tells what to cut, what fabrics to use and how to cut. • Computer guided spreaders provide distortion free garment spreading at high speeds to enable cutting. • Markers are put on top of fabric and cutting is done by hand or computer via laser beam or water. • Bundling is the process of sorting out cut pieces and organizing them for assembly.
Gini Frings Upper Saddle River, New Jersey 07458 Garment Assembly • Garment assembly, or operations, are based on operation sheets, where all necessary operations are listed in sequence. • Sewing operations must be performed in sequence. • The three methods of construction are: – Progressive bundling – Whole garment system – Modular manufacturing
Gini Frings Upper Saddle River, New Jersey 07458 Garment Assembly • Computer technology is used in garment assembly: – Computer Aided Manufacturing (CAM) – Unit Production Systems (UPS) – Computer simulation – Flexible manufacturing • Three main types of power sewing machines are used in traditional factories: – Lock stitch – Chain stitch – Overlock or serging
Gini Frings Upper Saddle River, New Jersey 07458 Garment Assembly • While programmable sewing machines are very successful in surging or seaming, automated sewing remains difficult. • Finishing is the handwork done inside collars and lapels to form and hold shape. • The high cost of skilled labor has driven this tailoring to fusing or machine basting.
Gini Frings Upper Saddle River, New Jersey 07458 The Final Steps of Garment Production • Dyeing ensures perfect color match between garments. • Washing is used in jeanswear to finish garments. • Pressing vastly improves the look of garments. • Quality control is the standardization of production using specifications as guides. • Labels showing a variety of information are sewn in. • Many retailers require “floor ready” standards: – Preticketing garments with bar coded price tags – Hang merchandise on Voluntary Industry Communications Standards (VICS) hangers
Gini Frings Upper Saddle River, New Jersey 07458 Shipping from Global Contractor to Manufacturer’s Distribution Center • Another choice is the method of shipping from manufacturer to retailer • Three main methods are used: – Free on Board (FOB) where contractors deliver goods to the ship or plane in the country where it is made. Manufacturers arrange and pay for transport and duty. – Landed, Duty Paid (LDP) where contractors ship to the distribution center and pay duty. – Cost, Insurance, Freight (CIF), pays for insurance and freight to final destination.
Gini Frings Upper Saddle River, New Jersey 07458 Shipping from Global Contractor to Manufacturer’s Distribution Center • Finished goods take approximately 4 to 35 days on water via ship and 3 to 10 days via airplane. • They are delivered to either the manufacturer’s distribution center for direct delivery to retail stores, or to the retailer’s distribution center for distribution to the retailer’s stores.
Gini Frings Upper Saddle River, New Jersey 07458 Filling Orders and Shipping to Retailers • Garments are checked for quality, divided into groups according to style, color and size and put into stock. • Standardized purchase orders make pulling orders to fill easier, faster and more efficient. • Orders transmitted via Electronic Data Interchange (EDI) are automatically translated in Advanced Shipping Notices (ASN’s) and invoices. • ASN’s are sent to stores so they know what to expect. • Bar-coded boxes are prepared for shipment, with packing slips and addresses, allowing for on time delivery and quick checking at the destination.