Problems in clothing manufacturing in any form can potentially affect the assembly performance, quality of clothes and timely delivery. While there's no such thing because the “seamless” process of clothing manufacturing, knowing these problems and handling them within the right manner is that the solution. during this article we'll point those problems out and can share our knowledge on the way to resolve them successfully.
Communication issues
Poor communication between designer and manufacturer may cause misunderstandings and delays in production. Main issues in communication include failure to share Tech Pack changes, missing important information within the conversation thread and a really common one - the barrier .
Sharing Tech Pack changes
First of all, having a robust Tech gain hand may be a key. By strong we mean a well-defined detailed document with:
Technical Sketches
Sample Sizes and Measurements
Construction Details
Bill of Materials (BOM)
Stitches and Seams
Branding Artwork
Measurement Specs
Point of Measurement (POM)
Diagrams
A strong Tech Pack means manufacturer doesn't need to guess what to try to to .
Very often changes are applied to the Tech Pack during the manufacturing process. albeit the change is minor it's important to report back to the manufacturer regarding it. Otherwise it may result in production errors or delays.
These changes may include, but aren't limited to:
Raw materials. The client can plan to use a special quite fabric or a zipper. If the previous choice got sold out or they simply changed their mind.
Measurements. Minor changes in Spec Sheets are often applied or the entire fit are often changed.
Construction techniques like sort of finishing details.
We found that 69% of the delays and quality issues are often avoided if changes are clearly documented.
Conversation thread
As a technical designer I spend an outsized portion of my time period connecting with manufacturers. it's crucial to me to stay our conversation thread well organized and accessible at any time. and really often I even have to stay up with several threads with different manufacturers.
Language barrier
When manufacturing overseas the language issue can become a barrier. Before a designer or a manufacturer had to navigate multiple programs to translate a Tech Pack. Many hours and sometimes even days are spent to translate the Tech Pack into a language .
Production delays
Production planning and control are two of the foremost important aspects of the clothing manufacturing process. Precision in planning equates to on-time shipments of the acceptable supplies and their timely delivery to the factory. Production planning may be a complex process and wishes to be mapped out way beforehand , fairly often for the years ahead.
Production delays occur when the assembly team doesn’t receive the raw materials on time. Early delivery are often as harmful as late delivery, because early deliveries need additional storage capacity. Keeping your supplier on target is extremely important. Specify the expected shipping day early and follow up with them regularly.
In manufacturing, production timelines are a strong tool to stay all processes so as . By using them you'll keep track of the progress of each project and makes necessary adjustments if needed.
To avoid delays some companies hire an independent inspector for production monitoring. together with your specifications and requirements available an independent inspector travels to the factory and verify that the merchandise meets your expectations. Your inspector can tell you the assembly stage of every product: which piece is finished and which is packaged. they will also provide knowledgeable insight into which processes are taking longer than expected and why.
Check out this great read with more information about the way to avoid the assembly delays.
Production defects
Production defects cause wasted raw materials, extra manpower for sorting and eliminating issues and unforeseen overtime . All of that cause extra costs and lost money.
Let's just say production defects can happen albeit each side do their best. But there's how to attenuate production defects and affect them quickly if they occur.
Our main strategies to scale back production defects:
Product design
As we discussed before, a well-made Tech Pack may be a thanks to go. an equivalent applies to the merchandise design. repeatedly a poor design leads to product defects. Therefore it's vital to check the sample garment before manufacturing an entire run. Involving manufacturing engineer from the beginning of development helps tons . they will forecast the potential areas of concern at the primary stages of product design. Which potentially can save plenty of cash for the corporate .
Flexibility in production process
One of the ways to scale back the amount of production mistakes is being flexible. for instance , sourcing the most fabric overseas and buying lining from the local factory mill.
Even if the planning , materials and technical details are approved fairly often changing the course are often an answer . Sometimes the needed fabric gets sold out or the primary garment sample if not understanding . Being flexible, accepting these changes and that specialize in solving these problems are going to be an answer . albeit it means missing the deadline and spending longer on development .
Smart manufacturing
Using latest technologies like computer modelling or simulations has proven to be very effective. It allows to spot the defects and fix them within the early stages of the merchandise development stages.
For example, tools like Marvelous Designer or Clo3D allow you to simulate a garment on a model and check how it fits.
Preventative Measures
Preventative measures for the factory include ensuring that each one operating machinery is functioning perfectly. For the designer it means checking that the factory has high manufacturing standards. a corporation can learn that by travelling to the factory, communicating with manufacturers and seeing their samples in real world . confirm to see even the littlest things just like the quality of finishing, they typically define how the actual factory is committed to producing top quality products.
Quality Control
Correct garment measurements and dimensions are main aspects of garment internal control . Because fit and luxury of a bit of clothing may be a main factor for many consumers.
When sharing your garment specs with manufacturer set a tolerance for every point of measurement. Setting a little margin of error will make sure the garments are produced and inspected consistent with your requirements.
Some companies have internal control teams in situ . they're liable for ensuring that production follows the principles at every stage. The inspector will make the on-site tests to verify the garment's durability and functionality. These tests are very almost like the regular consumer use.
I hope it will help you.
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