The Construction Process By Which Pattern Pieces, Materials, And Trims Are Merged Into A Finished...
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Transcript of The Construction Process By Which Pattern Pieces, Materials, And Trims Are Merged Into A Finished...
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Production Processes and Quality Assurance
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What and Why
Production:– The construction process by which pattern pieces, materials,
and trims are merged into a finished apparel product.
Cost of production– Affected by product design and pattern– Affected by the process
Designers and pattern makers need production knowledge
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Manufacturing Environments
Mass productionShort-cycle production Mass customizationWhich one depends on– Product type– Replenishment strategy
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Mass production
Very large quantitiesEconomies of scaleStaple productsLow fashion riskBased on in-store replenishmentSeasonal and staple good demand is easier to forecast.
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Allows for longer lead timesCan source off-shore and save on laborMexico and CB
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Short-cycle Production
Producst produced closer to time of market demandHigh fashion goodsShort selling seasons (6-8 weeks)No intention of in-store replenishmentAsia– Fabric availability– Skill levels
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Mass Customization
Short cycle manufacturing to an individual consumerAll the newest technologies– Body scanning– Pattern alteration software– Virtual try-on– Ink jet fabric printing
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Involves the customization of fit, design and personalizationProduct already designed– Customer “customizes the product”
Fit customization– Difference between the standard and the customers
needed adjustments– Body scanning
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Design customization– Fabric– Sleeve– Color
Personalization– More than just initial
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Advantages– Reducing inventories– Minimizing returns– Reducing distribution costs– Customer relations– Brand loyalty– Consumer research
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Production Sewing Systems
Single-handed– Samples and prototypes– Couture
Progressive Bundle– Common– Bundles rolled from one machine to another– Piece rate pay– High level of WIP– Bottle necks with varying speeds
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Unit production system (UPS)– Garment parts fed on over head conveyors
• One garment at a time– Cross training– Reduced operator handling time– Equipment investment
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Flexible Manufacturing Systems (FM)– Modular manufacturing– Self directed work teams– Entire garments– Paid on quantity and quality
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Factors– Downtime very critical– Investment in training– Support from management– Cultural change– Employees need to think and perform differently– Increase in quality– Reduction of WIP
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Agile manufacturing– Uses all the newest technologies– Mass customization– Flexibility in process
Combination of systems
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Developments
Faster industrial machinesSpecialized machinesStandup sewingEquipment maintenance is criticalNoise and air pollutionComputerized sewing machinesrobotics
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CAD/CAM
Computer aided manufacturing– Increase speed and accuracy of
• Pattern making• Market making• Grading• Cutting sewing
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Improved product qualityReduced production timeDiversified product line
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CIM
Computerized Integrated Manufacturing– Everything is linked– Smooth flow of information– Linkages to CAD/CAM
• Costing efficiencies• Spec sheet development• Numerically controlled stitching machines•
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Production Process
Determine the process that is most efficient and cost effectiveConstruction specifications– Sewing sequence– Fusing interfacing– Applying embellishment– Pressing– Hang tags– Folding– Packaging
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Considerations– Equipment capabilities– Labor costs– Subcontracting– What can be done prior to sewing process?
Problems– Procurement of materials
• Fabric, zippers• Subcontractors• International sourcing issues
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Finishing
Pressing and packagingAdding labels and bar codes– Floor ready merchandise
RFIC– Radio frequency ID chip
Fabric– Laundering– Stonewash– Pre shrink– Garment dyed
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Quality Assurance
Meets the standardsASTM and AATCCAdhere to spec sheetsFabric inspection– On-grain– Dye lots
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Sewing and finishing– Stitches– Seams– Edges– Button holes– Hems– Plaid matching
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Finishing– Thread trimming– Closure placement– Shoulder pads– Linings– Pressing
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What if they don’t meet standards– Refuse shipment
• May not be able to replace• Stock outs
– Seconds in outlet stores
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Logistics Agents
Export agent– Assists with exporting product out of contracted
country
Freight forwarding company– Move goods from country of production into the US
Customer broker– Help with customs