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Garments manufacturing sequence in an industry is given below:
- Design / Sketch
- Pattern Design
- Sample Making
- Production Pattern
- Grading
- Marker Making
- Spreading
- Cutting
- Sorting/Bundling
- Sewing/Assembling
- Inspection
- Pressing/ Finishing
- Final Inspection
- Packing
- Dispatch
Design or Sketch: Designing is the first step in garment manufacture where in the entire garment along with accessories and design details is sketched out by the designer. Along with this working drawings are also drawn. Working drawings are flat drawing of the sketch and it helps pattern maker in understanding the patterns involved in garment construction.
Pattern Design: the basis for any garment is a pattern. The pattern is made as per the standard sizes of Men and Women by drafting method. A good pattern gives a good fit and saves time and increases the rate of accuracy in garment making. With the help of a pattern, a sample garment is made for test fit.
Sample Making: The patterns of the earlier step are sent to the sampling department to make a sample of the final design/sketch. This sample is constructed to analyze the pattern fit, design and also for approval from buyers. Samples are required at various stages to get approval from buyer. As per the development stages samples are named as Proto sample, Fit sample, Size set sample, Sales man sample, production sample, Top of production (TOP) sample and shipment sample. This is an essential step before going for a bulk production. Once the sample is adjudged right, then it can go for bulk production.
Production Pattern: From the final pattern, a production pattern apt for bulk production is made on a pattern paper. Garment patterns can be constructed by two means: manual method, CAD/CAM method. The advantages of CAD/CAM are multifold - ease of designing patterns, fluency and precision, easy storage, modification of patterns at any time.
Grading: Grading to create patterns in different standard sizes by scaling either up or down, to fit for various sizes. The common sizes seen in the apparel are S, M, L, XL, XXL sizes. Grading through CAD is easier and faster when compared to manual grading.
Marker Making: All the patterns for a style are laid out on a marker which helps in estimating the yardage for a required quantity for apparel. It also helps to minimize fabric wastage. Such markers can be fixed to the fabric by means of adhesive or staples.
Spreading: Once the maker is ready, it has to be placed over the lay. A lay consists of several lengths of fabric laid one on top of another by spreading the fabric bolts on a cutting table. Laying can be done either manually or through spreading machines.
Cutting: Cutting can be accomplished by means of various cutting devices like, round knife, band knife, die cutters, laser cutters etc depending on the thickness of the lay.
Sorting & Bundling: Patterns cut will have to be sorted and bundled as per sizes and design. On each bundle there are specifications of the style size and the pattern number.
Sewing & Assembling: In this process all the cut components are assembled together to make the apparel as per the buyers requirement/design.
Inspection: The finished apparel is inspected for open seams, improper stitching techniques, mismatched threads, skipped stitches, improper creasing of the garment, erroneous thread tension and raw edges etc. This is generally the work of the quality control department. If any defects are they are rectified.
Pressing or Finishing: The final operation that adds to the overall look of the garment is the finishing operation. It can be done manually or by use of machines.
Packing: The pressed apparel is sorted as per design, size and packed as per the buyers instructions.
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