As we all know in today’s scenario (after pandemic), we all got to offer a touch extra and work more efficiently to remain in competition. Either we provide products at less price or deliver goods at a faster rate than the competitor. If not we'll be out of the market in no time. As staple (fabrics) and labor cost are increasing day by day. So, reducing cost isn't a simple task.
To reduce the value we must find ways to eliminate non-value added activities from the system and achieve 100% FTR. Rejection and rework amounts to an enormous percentage of wastage which is neglected by many factories.
Sampling is one among the foremost ignored areas, when it involves planning of garment deliveries. We fail to include required sampling time while planning and later suffer at the time of delivery blaming one another and asking extension from customer. Moreover sample rejection (which is extremely common) makes things worse.
Also Read: Why Apparel Fit Samples Are Rejected?
Challenges faced during sampling which ends up in delay in sample or rejection (internal or external) of sample:
Not having adequate information from customers for sample development like construction details, fabric/ trims confusion, etc.
Poor communication between merchant and sampling team which ends up in rework.
Unavailability of raw materials like labels, buttons during sampling.
No or less clarity to sampling QC on the need of the customer in terms of quality parameters (especially, just in case of latest buyer).
Less understanding of buyers tech pack to sampling operators.
Rejection of sample after making thanks to fabric issue (like fabric defects or shade present).
So of these issues are faced by factories which ends up in delay in submitting samples to customers or higher risk of sample rejection. One sample rejection can waste 7-10 days which can directly affect garment delivery. FTR in sampling must be monitored and steps should be taken to make sure sample passes in one attend save time. during this article, we'll discuss the way to achieve 100% FTR in sampling so on get approval on samples at a faster rate with none rework.
The following measures are often incorporated so on eliminate above mentioned challenges during sampling:
1.Sample Needs to be Developed: Before delivering the sample request to the sampling, a merchant must take complete clarity from the customer about the sample. this could be done during proto/fit sampling as 80% of things are closed at this stage. Merchant can make a checklist to make sure he/ she has all the specified information about the sample. An example of a checklist is shown within the following figure:
This sheet will help to gather all required information from customers in one go. Either we will send this to the customer to fill or we will collect information from him through mail or call. This checklist are often updated at regular intervals as per requirement.
2.Having all Information about the Sample: Poor communication between the merchant and sampling is that the biggest reason for sample failure and delay in submission. repeatedly a merchant verbally informs the sampling department about the sample and there are not any proper records of the verbal communications. thanks to this there'll be an excessive amount of to and fro between the sampling, QC and merchant which ends up in delay or rejection. If everything isn't properly communicated there are chances of things missing out and rejection from customers leading to re-submission. supported the above sampling checklist, merchants can prepare a sample indent containing all information and submitting to sampling. An example of same is shown within the Figure-2.
It will eliminate any chances of error which may cause any issue. This indent are often employed by the sampling team while making samples and by QC to see the sample.
3. Complete Package of Fabric and trims while Handing over to Sampling: Sometimes few things are forgotten and not handed over sometimes . this may end in hampering work thanks to unavailability of fabric . for instance , buttons are missed to offer . Now the sample is prepared but cannot be dispatched thanks to buttons pending. this may cause delay in sampling. So merchants should make an entire package of all the trims and fabric and hand it over to sampling directly . If anything is missing then it must be told at the time of giving sampling indent. Sampling department should check all the fabric while taking the indent from a merchant. this may save tons of your time and end in faster sample delivery.
4. Making a internal tech pack for easy reference for operator and checker: Many times the buyer’s tech pack isn't easy to know by the standard checker or sewing operator or maybe by the supervisor. Also each buyer will have a special format of tech pack. this will end in misunderstanding of technical details. To avoid this problem we will make a simple to know tech pack with a standard format in order that operator and checker can read and understand easily. this will be made by QA by hand or by CAD software with diagrams. this may help to urge clear and fast information like sort of seams, basic measurements like height, width, placements of labels and buttons, etc. this may help operators in making samples as per requirement with none confusions. The checker also can use an equivalent regard to check the samples. Also these sheets are often utilized in sewing during bulk production of an equivalent order.
5.Issuse of Sample Rejection: We all have faced these issues repeatedly in our life. After the sample is fully made then some shade problem is seen could also be thanks to CSV present in fabric, or fabric defects, or excessive shrinkage in fabric or labels or tapes used. We always check the material and trims for bulk production on multiple parameters but fail to see the material given to sampling. Samples are generally made up of the yardage received from supplier or customer and directly handed over to sampling for sample development on faith . There might be any problem present within the yardage which can bypass and end in sample rejection. So always fabric yardages and trims should be checked for defects, shade, and shrinkage. If any problem found counter measures must be taken or should be highlighted to the customer beforehand . nobody wants to reject the sample after making it thanks to basic fabric issues.
Conclusion:
Following above measures will help to eliminate causes of sample delay or sample rejection which can improve our working. If sampling activities happen on time with none failure or resubmission then orders are often delivered at a faster rate. it'll also boost customer satisfaction and improve factory performance.