Production Process
ApparelTASKER receives hundreds of enquiries, the most asked questions surround our process of how to begin and which steps to take.
Steps to Clothing Manufacturing
Mindset
Before we outline the steps of the clothing manufacturing process, having the right mindset is crucial. There are variables which will allow the process to run smoothly, if you are aware of them.
Understanding the time frame of the manufacturing processes; We provide a general guideline for a production of 3 months. This happens after the completion of patterns and samples which in itself can take 2 weeks to 2 months depending on the garments and scheduling.
Completing patterns and samples may take up to 4 weeks however, if we are able to finish the production sooner we will. There are many aspects of the production process which need to align in order to make the process run smoothly. The process may vary based on sourcing fabric, hardware, woven tags, swing tags, mass production, shipping, QC, etc. In most cases, the first productions will take longer than those that follow.
By manufacturing with us you will be producing ethical garments, providing ethical living wages for families and supporting local communities.
Tech Packs and Quotes
The first item we will need from you is a tech pack. Tech packs include full design details such as measurements, fabrics, printing techniques, lining details and supporting images for the garments you’re looking to have produced.
In the interest of efficiency it is best to include as much detailed information as possible. Based on your completed tech packs, we will then be able to provide you with a quote on production costs.
It is important to note that this quote is an approximation, and as much as we do our best to stay within that quote there are factors that could require more time on your garment.
Depending on the complexity of design, amount of pattern pieces and cuts and stitches needed this will impact your cost.
Note: all of our quotes are C.M.T and do not include material or sourcing.
Sourcing Fabric and Hardware
Sourcing materials and fabrics can be a daunting process, with a variety of textures, patterns and end uses, where do you begin?
We always suggest to have a general idea of which materials and fabrics you want to work with before going to suppliers.
Once you’re at that stage we can provide guidance as to what might be the best fabrics based on your designs. Going into this process without any idea of which fabrics you’d like to use could greatly impact the timeline of your production.
Popular fabrics will come in a variety of pre-dyed colours. If the fabric doesn’t come in the colour you want, which is a common occurrence, it will need to be custom dyed to the colour you choose. This will also often come with higher MOQs depending on the supplier.
If you are looking for printed fabrics, it is possible for the design you like to be available but not in the material you want. In this case, the supplier should be able to assist you by providing printing services in-house or the name of another company that can screen or digitally print fabric out of house. Keep in mind when printing fabrics (or dying them) there are MOQs for this, be prepared to produce more than a stock fabric.
Alternatively, rather than buying fabrics that may not be what you want or need for this process, manufacturing the textile right from a mill might be a good option for you.
Development
Patterns, Sample and Grading
Once you have confirmed your production cost quotes and sourced all materials, you are now ready to have patterns and samples made.
The cost of this process is normally the production cost x4 or 5 which varies between type of garment. We charge separately for the patterns and the samples, so make sure to speak with us and ensure you are getting what you expect.
Your pattern is made up of all information provided in your Tech Pack (or physical samples provided) illustrated onto drafting paper. This will then be used as a template and laid onto the fabric to trace and cut out. Once all of the fabric pieces have been cut out, they will be sewn together to create your samples.
The samples are primarily there to make sure fit of the garment is correct before going into full production. This is also before deciding on details such as fabric, printing techniques, colours and woven tags etc. The initial sampling phase will usually take anywhere from 1 to 4 weeks depending on the design’s complexity.
Along with your tech pack it’s best to also provide a sizing guide you’re comfortable using. There are many different options with UK, American, European, Australian etc sizing. This is an important aspect as whichever one you choose will be used to grade all of your patterns.
Review of Samples
Once development is completed you will have time to review your samples.
What you will be looking for is the feel and fit of the fabric— Does it sit correctly? Does it flow and fit as you Envisioned? If not, you might need to change your choice of fabric and start the sampling process again. Do keep in mind, you will be charged extra for this.
Be sure to check all of the seams in the garments, give them a good pull to ensure their strength. Wash them according to the clothing care instructions to ensure they withstand the wash and dry cycle – do this 3-4 times.
If there are any changes required, communicate this very clearly to us using centimetre increments.
When making corrections, use the following tips and guidance;
1. Post the samples back to us with detailed instructions attached to the garment in the area that needs correcting.
2. Take photographs of the pieces and make edits directly on the photograph by circling specific areas and adding text so help us understand exactly what you’d like altered.
Samples are a trial and error process, so be prepared for the possibility of corrections.
Pre Production
You now have perfect samples or “master samples” and are ready to proceed to pre-production.
This process includes a variety of steps, some of which may apply to you and others which may not - which are all dependent on your production.
Some preparation steps include:
Ordering all fabrics and materials: This will take approximately 1-2 weeks from placing the order with the suppliers to delivery. If the fabric or materials are not available at that time you’ll then need to order directly from the textile producers which can take up to 2 months.
Accessories or hardware: This includes buttons, zippers, snaps, eyelets, press studs, buckles etc. These items can take up to 4 weeks for delivery if a special order or customisation is required.
Elastic or framilon
Production and Quality Control
Once all of “Step 6” is in place and ready, the bulk production can begin; the CMT (Cut, Make, Trim).
The general timeframe for a production is 1-3 months. Though this will vary based on the total amount of pieces in your production, the complexity of designs, as well as what other productions are in the schedule at that time. The preparation for bulk production would be included in this 3 month timeframe.
During the bulk production process quality control is of the utmost importance. This will be performed by randomly checking approximately 15-20% of all completed pieces up until the packing point. This will allow any errors to be caught and corrected in a timely manner without impacting the completion date.
After receiving your production you will be given time to review the pieces for QC. If you do find any rejects send these back so that we can repair or replace them for you.
with in 3 days of production delivery. We will then press and pack your garments, and ship directly to you or your warehouse.
Thank you for reading!
We hope this has given you a better understanding of how ApparelTASKER and the garment manufacturing process works.