Production Departments In RMG Industry

PDS Department
Cutting Department
Sewing Department
Washing Department
Finishing Department
Packing Department

There Duties In Combine

Patterns and Markers:

Pattern making, grading and markers are a crucial part in planning for production.
Once markers of each style are based, you can easily calculate the yield of fabric
needed for your production and in turn order your fabric.

Ordering Fabric:

Order fabric based on the yields needed in order to meet your production needs.
When planning your production schedule speak with your fabric supplier about the
turn around for your fabric and any additional time needed for dying or washing
your fabric.

Other Materials:

Order other materials such as buttons, grommets and zippers prior to your
production. These elements are often overlooked but crucial in the production of a
garment.

Scheduling Contractors:
Meet with your sewing contractor prior to the beginning of the time period you need
your production completed. Create a contract with your sewing contractor stating
sewing prices, turnaround time, and list what your contractor is responsible for
providing and what you are responsible for. Make sure to have deadlines for all
these elements.

Overseeing Production:

Once production has begun, you should check on your items regularly to make sure
everything is being produced up to your standards. The first item off the line
should be given to you for approval, make sure this is stated in your contract. Be
sure to immediately check your production thoroughly for any mistakes.

Finishing:

Many sewing contractors also offer finishing services such as pressing, folding,
tagging, and bagging items. If this is not the case, allot plenty of time for your
finishing needs.

Considerations:

It is commonly known that the garment industry is late with orders, while stores
and boutiques expect their orders to be on time. Give yourself a cushion of a few
days whenever possible in order to make sure your production is on schedule. Make
sure to have a contract with your sewing contractors defining the finish dates and
any penalties that apply for a late production

Schedule:

Creating a time frame is the most crucial part of garment production planning.
Working backwards is the best way to determine this schedule. Determine a finish
date for your production and move backwards from that.

Inspection and Finishing:

Be sure to allow time to inspect your sewn garments before they are finished. Many
times, sewing contractors will give you only a few days to return items for them to
fix. You do not want to send defects out to your stores. Once inspection is
completed, pressing, tagging and bagging are the final production planning stages.
Select a finisher and determine the time needed to finish your production
depending on size and requirements.
Cutting and Sewing:

Many sewing contractors also offer cutting services. If this is the case, include this
time in your contractor's schedule, otherwise, use a cutting contractor. Once you
select a sewing contractor for your production, they can tell you the time frame
needed to sew your garments. Create a contract stating the schedule with your
sewing contractor. Determine what they will provide, such as thread and what you
will provide. It is advisable to provide a sewing instruction card along with sewn
samples for the contractor.

Fabric and Materials:

Ordering materials is a crucial element in beginning production. If your items

require materials from multiple vendors this coordination can become more difficult.
Be sure to give appropriate lead times for your orders depending on when your
sewing contractor needs materials for production.

Patterns, Marking and Grading:

This is the first step of production planning and if often finished after sample
making. Once orders are in place, get your patterns and grading completed. Your
markers will determine the yield of fabric needed for your order. Once markers are
complete, fabric can be ordered.

Design/ Sketch:

For the production of knit garments, or woven garments a sketch of a particular

garment including its design features is essential to produce on paper so that after
manufacturing of that garment could be verified or checked whether could be done
manually or with the help of computer.

Pattern Design:

Hard paper copy of each component of the garment of exact dimension of each
component is called pattern. The patterns also include seam allowance, trimming
allowance, dirt’s, and pleats, ease allowance, any special design etc affairs. Pattern
design could also be done manually or with the help of computer.

Sample Making:
The patterns are used to cut the fabric. Then the garment components in fabric
form are used to sew/assemble the garment. Sample garment manufacturing is to be
done by a very efficient and technically sound person.

Production Pattern:

The patterns of the approved sample garment are used for making production
pattern. During production pattern making, sometimes it may be necessary to
modify patterns design if buyer or appropriate authority suggests any minor
modification.

Grading:

Normally for large scale garments production of any style needs different sizes to
produce from a set of particular size of patterns, the patterns of different sizes
are produced by using grade rule which is called grading.

Marker Making:

All the pattern pieces for all the required sizes are arranged n the paper in such a
way so that maximum number of garments could be produced with minimum fabric
wastag4e. Markers are made for 6, 12, 18, 24 etc. pieces. Marker is also useful to
estimate fabric consumption calculations.

Spreading:

It is the process of arranging fabrics on the spreading table as per length and width
of the marker in stack form. Normally height of the lay/fabric is limited up to
maximum six inches high. But 4 inch to 5 inch height of the lay is safe.

Fabric Spreading:

Spreading means smooth lying out of fabrics as per marker length and width.

Interlining:

Interlining is one kind of trimmings which is placed between two layer of garment
parts in garment manufacturing

Lining:
Lining is one kind of trimmings which is used underside of garments and use in next
to skin.

Fabric Cutting:

On the fabric lay/spread the marker paper is placed carefully and accurately, and
pinned with the fabric to avoid unwanted movement or displacement of the marker
paper. Normally straight knife cutting machine is used to cut out the garment
component as per exact dimension of each patterns in stack form, care must be
taken to avoid cutting defects.

Sorting/ Bundling:

After cutting the entire fabric lay, all the garments components in stack form is
shorted out as per size and color. To avoid mistake in sorting, it is better to use
code number on each pattern.

Sewing or Assembling:

It is the most important department/ section of a garment manufacturing industry.

Sewing machines of different types are arranged as a vertical line to assemble the
garments. Sequence of types of sewing machine arrangement depends on sequence
of assembling operations. Number of sewing machine per line varies from 20 nose to
60 nose depending on the style of the ga4rmnet to be produce. Production pr line pr
hour also varies from 100 to 150 pieces depending on specific circumstances.
Number of sewing machine arrangement per line may be up to 60 depending on
design and out put quantity of garment.

Inspection:

Each and every garment after sewing passes through the inspection table/ point,
where the garments are thoroughly and carefully checked to detect/find any
defect if present in the garment. The defects may be for example variation of
measurement, sewing defect, fabric defects, spots etc. if the defect is possible to
overcome, then the garment is sent to the respective person for correction. If the
defect is not correctional, then the garment is separated as wastage.

Pressing/ Finishing:
After passing through the inspection table, each garment is normally ironed/
pressed to remove unwanted crease and to improve the smoothness, so that the
garments looks nice to the customer. Folding of the garment is also done here for
poly packing of the garments as per required dimension.

Final Inspection:

It is the last stage of inspection f the manufactured garments on behalf of the

garment manufacturing organization, to detect any defective garments before
packing.

Packing:

After final inspection, the garments are poly-packed, dozen-wise, color wise, size
ratio wise, bundled and packed in the cartoon. The cartoon is marked with important
information in printed form which is seen from outside the cartoon easily. 15.
Dispatch: The cartoons of the manufactured garments are delivered or placed in
the dispatch department or finished product go down, from where the garments lot
is delivered for shipment.

Bespoke Garments:

Bespoke Garments are made on the basis of individual clients and according to the
individual’s size and requirement.

Ready to Wear Garments:

Ready to wear garments is made on the basis of target common groups, according to
size charts, derived from statistical analysis.

Links
http://articles.textileclass.com/garments-manufacturing-sequence/
http://www.ehow.com/about_5394011_garment-production-planning.html

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