Is the clothing manufacturing process super complicated or simply patching pieces of colored fabric together? Whether you’re wearing a super sparkly outfit or simply a plain blue t-shirt, you’ve probably wondered how this thing is made. If you still do not have the answer, let’s learn about the basic process of making clothes with Dugarco in the following article.
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1. Summary of steps in the clothing manufacturing process
The manufacturing process for clothing is never fixed. Here are 12 basic steps of manufacturing process that most of the process of making all clothes must go through.
1.1 Pre-production stage
This stage is an important stage in the cloth manufacturing process as it contributes to a more complete and quality product. This phase consists of two main steps of manufacturing process including “Fabric and Trim Sourcing” and “Pattern Making”.
1.1.1 Fabric and trim sourcing
In the steps in manufacturing process, after the final design was completed, manufacturers began to turn to experienced professionals for advice on choosing the right fabric. They can then start producing fabrics in their own company or buy from reputable partners. After receiving the fabric, they can check the quality, if it meets the standard, the fabric will be used in the production process. After the fabric is selected, it will be taken to the cutting area. Then fabrics are aligned manually or mechanically to become uniform plies.
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1.1.2 Pattern making
The pattern-making process is very important in the clothing manufacturing process because it greatly affects the quality of the final product. This production process steps can be done on flat paper or flat fabric. Often the manufacturing process of clothes on flat paper is more common. Since the pattern can be removed from the paper more easily. The type of paper they usually use is called pattern paper. Using modern techniques, they break down designs into 2D pieces, then create different individual pieces of clothing.
1.2 Production planning
The manufacturing process for clothing must be scientifically organized for everything to go in the right direction, closely, efficiently, and on time. Everyone understands what to do and when to do every step in the manufacturing process steps once the strategy is in place. A great plan also makes it easier to reach the project’s targets. Furthermore, when planning, manufacturers anticipate some risks to deal with them more flexibly in the future.
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To ensure quality in the clothing manufacturing process, careful grading is essential. Grading is the manufacturing process steps in a range of sizes for a single garment type. Grading is used to correctly fit a design to a range of sizes. Grading just increases or decreases the size of the previous shape. When you have your pattern and your fit for a middle-sized size is accepted, the pattern is “graded” for the size range you choose.
The “grading guidelines” will enable the producer to methodically increase or reduce the middle-sized design depending on the required size. For each measurement point, the “grading rules” refer to the amount of change between sizes. Grade rules are typically 1′′ from 0-10, 1′′1/2 from 12-16, and 2′′ up from 18 with a 1/4′′ length difference between sizes. So a size 4 will only be graded down 1 inch (half an inch in the front and half an inch in the rear) to produce a size 2.
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1.4 Cutting process
To make the best use of a company’s fabric resources, an efficient cutting process is essential. The fabric-cutting procedure requires extreme precision. Because it is quite difficult to recut the fabric once it has been cut incorrectly. Only an inaccuracy in the cutting process can have a big impact on the manufacturing schedule and output. Cutting technologies that are more advanced than ever before such as laser-cutting, and heat are available to reduce errors and prevent wastage when cutting fabrics.
1.5 Marker making
There are two types of marking including a manual marking process and a computerized marker-making process. The marker planner employs full-size patterns and puts them on marker paper in a cost-effective manner. This is a specifically printed paper with symbols on it that allow the marker planner to visually regulate the location of components according to specified grain lines. Markers made of paper are attached to the fabric by pins, staples, or adhesive paper that is heat-fused to the top layer of the cloth.
Spread specifics are provided via marker planning. The fabric is laid manually or with a spreading machine in the cutting room to arrange fabric inlays 100 (layers) and markers for the manufacturing, any in orders planned. Fusible, linings, trimmings, and other materials are also planned here. The spreads are detailed in marker planning. Marker planner supervisors arrange and assign cut orders to various activities to be carried out in the cutting room.
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1.6 Cutting parts sorting or bundling
The next step in the clothing manufacturing process is cutting parts and sorting. According to the production system, cut components are sorted. When sorting, all of the components of a garment are grouped. Size sorting is essential, as is color sorting if many colors are cut on a single layer.
“Bundling” is the process of deconstructing and reassembling stacked and cut components in production lots organized by garment unit, color dye lot, and number of garments. The cutting is now ready to be sent to the production line for sewing. Manufacturers utilize a variety of packaging methods based on their demands, with four main systems being the most frequent among local manufacturers including item bundling, group bundling, progressive bundling,…
The fabric is sent to the sewing area after it has been cut and bundled according to size, color, and quantity. Each worker will be in charge of a certain part of the product in the assembly line. For example, in the cotton cloth manufacturing process, the first person will be responsible for sewing the collar, the next person will sew the body, and another person will be responsible for the sleeves,… Each person repeats his or her assigned work until it reaches the target. After each part is completed, it will be moved to a certain area to assemble the discrete pieces into the finished product.
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1.8 Quality control
To ensure that the quality of the product meets the client’s requirements, the manufacturer needs to have a thorough inspection action. Usually, the quality check manufacturing process of clothes is done right from the production of the garment to make sure everything is on the right track and to catch errors. So that they can be fixed in time in the cloth manufacturing process. After the products are completed, businesses also need to check again on quality as well as quantity to minimize the situation of returning goods from clients. There are several ways to make the quality control manufacturing process steps most effective:
- Creating a standard to serve as a criterion for evaluating quality performance.
- The output of the steps in manufacturing process can be measured and compared to the planned quality standard.
- If there are any deviations from the plans, corrective actions must be taken.
A thorough examination of each step in the manufacturing process for clothing helps you anticipate possible risks. This would result in higher production efficiency.
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1.9 Spot cleaning and laundry
In addition to being guaranteed the accuracy of design, fabric, and quantity, the product is also guaranteed not to contain aesthetic errors, stains, or other marks left after the cutting and sewing process. If any stains appear on the garment, it will be marked with a sticker and taken to the laundry area. Based on the agreements in the contract, the products after being manufactured will be laundered after being assembled.
1.10. Fusing and pressing
These are the two most critical phases in deciding what has the greatest influence on the finished look of a garment. While friction provides the groundwork, pressure leaves its mark on the clothing. Machines used to complete the mixing as well as pressure include hand tools with a vacuum pressure table, carousel machines, scissors machines, and a steam dolly.
After a garment is fully sewn and assembled, it is transferred to the ironing section of the facility for final pressing.
- Steam and heat are required to relax the fabric and make it malleable enough to be molded by manipulation during pressing.
- After the fabric has been softened by steam, pressure is applied to put the fibers into their new places.
- After applying steam and pressure, the component or garment must be dried and chilled so that the cloth can return to its original state. This is accomplished through a suction operation that removes excess water from the fabric while also cooling it. Hot air or infrared heating is utilized instead of a vacuum for drying in some pressure activities.
1.11 Packaging and shipping
At the end of the clothing manufacturing process, after being thoroughly inspected, the products will be neatly folded, labeled, sized, and packaged by the customer’s specifications. Other hanging clothing, such as coats, dresses, and skirts, are typically bagged by manual, semi-automatic, or completely automatic equipment. Additionally, clothing can be packed in protective plastic bags, to ensure that the material remains clean and pressed while shipping. Finally, the items are packaged in cardboard boxes and delivered to client distribution centers before being sold in retail stores.
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2. Main methods in the manufacturing process for clothing
In the clothing manufacturing process, there are two main methods commonly applied by businesses CMT and FPP
- CMT (Cut, make, trim): is one of the two primary types of garment manufacture. The CMT clothing production process includes services such as cutting, making, and trimming that transform initial supplies into completed products. You must be skilled in these operations to use this production approach.
- FPP (Full production package): Clothing garments go through all stages of manufacturing in FPP. Full production vs. FPP Package is a method of manufacturing clothes in which the supplier supplies all phases of garment construction to the brand. These stages are as follows:
- Pattern making
- Fabric and trim procurement
- Sample development and manufacturing
- Final clothing manufacture.
FPP includes both CMT and all other elements in garment manufacture. Producers consult with the brand in this sort of manufacturing, and after gathering the requirements, the initial sketches are utilized to develop the technical packets. This is a widely used strategy that aids with purchasing fabric and choosing.
Here are the pros and cons of these two production methods:
|CMT (Cut, make, trim)||FPP (Full production package)|
3. How to reduce the time for the clothing manufacturing process
There are a few things you can do to reduce time and optimize your clothes production process. Here are a handful of our recommendations:
- Improving your management of supply chains is one option. This involves making certain that your suppliers can meet their delivery deadlines and that you have adequate stock levels.
- Streamlining your operations is another technique to reduce time to market in garment production. This could entail implementing lean inventory principles or employing just-in-time management of inventory techniques.
- You should always stay connected with your supplier or retailer during the manufacturing process. Maintaining this relationship will help you get valuable feedback, thereby improving your processes, and ensuring the best quality for your products.
- The clothing manufacturing process does not need to be too complicated. You need to keep the manufacturing process steps as simple as possible to ensure the garment is manufactured to standards and to reduce the risk of manufacturing errors.
4. Distributor of quality clothing and apparel products in Vietnam
Since its beginning in 1990, Dugarco has been a key player in the Vietnam textile and garment industry. Dugarco is proud of its ability to meet the demand for extraordinarily large quantities of items. To have this capacity, the business owns 25 workshops, 165 manufacturing lines, and more than 8000 employees. The corporation has clients and partners all around the world, both domestic and international. Many well-known companies, like Calvin Klein, JCPenney, Costco, Nautica, and others, have placed their trust in the company and collaborated with Dugarco, bolstering the company’s standing.
Product quality is always a priority that Dugarco prioritizes. Dugarco’s primary product ingredients are organic cotton and recycled polyester. They not only help the environment, but they also make clients feel more engaged when wearing them. Each product line from jackets, shirts, uniforms, suits, knitting, and pants is produced by Dugarco with the most dedicated and meticulous attitude. However, with full of experience and smart strategies, Dugarco is confident to give you quality products at a reasonable price.
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The clothing manufacturing process at Dugarco is extremely complicated and goes through 15 steps:
- Drafting idea: Dugarco’s design staff will begin drafting patterns as soon as orders are received from clients. The customers have the right to respond and change if there are any problems.
- Pattern making: When a firm has to create hundreds of products of the same size and measurement, this step is crucial. After that, pattern grading for each size would be provided during the pattern-making stage.
- Material selection: The fabric will be selected by the manufacturer based on the quality and color requirements specified by the clients.
- Making samples: Following that, samples will be made based on the previously defined pattern. Typically, 2-3 samples are manufactured initially to determine whether the clothes parameters are acceptable and adequate.
- Fitting: This testing stage assists Dugarco in identifying and precisely assessing the fit of the design corresponding to various product sizes.
- Purchasing material: Once the fitting clothing production process is complete without errors, Dugarco will contact fabric suppliers to agree on the quantity of fabric to be acquired in connection to the number of units of products to be created.
- Material for inspection: Whether the fabric used in manufacturing meets the standard will be determined by a third party. This is done to ensure that the finished product is of the highest quality.
- Pre-production meeting: At Dugarco, an internal meeting will be organized to ensure that each team understands the procedure and special demands for the clothing manufacturing process that fulfill client criteria.
- Cutting: During these steps in the manufacturing process, Dugarco can detect and precisely assess the fit of the design corresponding to various clothes sizes. As soon as there is an appropriate supply of fabric, fabric cutting will take place on a level surface. A cutter will be used to cut multiple layers of cloth at once. However, the cutting lines will be pre-marked before cutting to ensure precision and reduce fabric waste.
- Bulk production: At this stage, skilled tailors will start working on the product line. Several sewing machines will be running at the same time throughout manufacture to ensure production speed and consistency.
- Quality control: Just like with fabric quality checks, a third party will verify the products for flaws before they are dispatched to the buyer. Damaged items will be fixed or replaced if this is the case.
- Needle inspection: These important steps of the manufacturing process not only protect the quality of the finished garment but also the safety of the client by lowering the potential of needle injuries.
- Packing: The workers will then attach the clothes with hang tags and price tags. Following that, the goods will be packed in poly bags or follow the client’s requirements.
- Humidity: Dugarco will keep the shirts at the proper humidity level to minimize damage before distributing them to consumers.
- Delivery: The final products will be shipped to the clients through the proper form of transport.
All steps in the manufacturing process are meticulously performed under strict supervision. Everything is carefully planned and there are risk management plans in place in case any problems arise. Therefore, the clothing manufacturing process at Dugarco always ensures high quality and efficiency.
With many years of experience, Dugarco always takes the right steps in its working process. Some outstanding strengths can be mentioned:
- High product quality: All products are examined by a third-party inspection organization. The quality defect rate is less than 1% once the garment is delivered to the customer
- On-Time delivery: In 2019, 98% of orders were delivered on time. Up to now, no customer has returned due to late delivery.
- Advanced manufacturing technology: Dugarco always focuses on investing in the most advanced equipment to improve production efficiency. Specially. the company is expertise in designing unique down jacket pattern
- Professional in material sourcing: With a large network of partners, Dugarco can find a variety of fabrics from the most reputable sources.
- High value of production in Vietnam: Dugarco is a prominent enterprise in Vietnam, where there is an abundant labor force, and a large labor market, bringing many benefits to the production and distribution of products. Besides, the policies of the Vietnamese government are also very attractive for the development of corporations.
In this article, Dugarco has taken you through each step of the clothing manufacturing process. You will feel amazing because behind those simple clothes is a powerful team that gradually perfects it through many stages. After having a better understanding of the clothing manufacturing process, hope that you can come up with more accurate criteria for choosing your manufacturer. We believe you find this information useful and interesting. If you have any questions or feedback, feel free to contact us.
- Address: 59 Duc Giang Street, Duc Giang Ward, Long Bien Districts, Hanoi City, Vietnam
- Tel: 024 3655 7930
- Email: email@example.com
- Website: https://dugarco.com/en/
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Dugarco under the talented leadership and guidance of Mr. Hoang Ve Dung has gradually become a large Vietnam clothing manufacturer, supplying clothes for many famous brands from many different countries such as the UK, USA, and Australia.