Monday, May 28, 2012
Manufacturing a Garment Pieces and Woven Fabric
Consequently we often see the adverse effects of poor fabric sourcing strategy every day in the apparel industry. Garment air shipment cost is prohibitive and applied as penalty only when the apparel manufacturer fails to deliver the consignments beyond acceptable delays. The cost of air-freight is so high that air shipment of a single consignment of garments may wipe off the profit of a few months for the garment manufacturer. A study revealed that more than 80% of all garment air shipment is caused due to poor fabric sourcing management.
Fortunately, such critical errors can be avoided when sourcing woven fabric for manufacturing garment and the procedure is easier than we think about it. When discussing with the garment buyer, do not just talk about the target price he or she is giving you. Ask about the fabric in more detail. This is not only about the counts, construction and weight of the fabric but about some important and critical points. Here are may 7 tips to ensure a trouble free fabric sourcing.
1) Know the end use - that clarifies the required quality standards like colour fastness, piling / abrasion resistance, tear and tensile strength, stability towards special types of garment wash if any etc. Do not feel hesitant to ask those questions because at the end of the day if something does not match the buyer's requirement everyone will suffer losses.
3) The garment delivery lead time should be calculated after taking the fabric delivery lead time into consideration. Many garment buyers demand very short, sometimes unrealistic delivery lead time. You should consideration the lead time required for each necessary activities like LC opening, sample approval, lab dip approval, one or two re-submits that may be required, inspection and shipment time for the fabric, clearance and transportation to the warehouse and all related activities.
4) Inspection of the fabric and grouping those according to shades are to be done with extra care. For example, if one particular colour is having a large quantity, it is natural to have 2-3 batch wise variation. Mixing shade batches on the cutting table can result in disaster. To make the process easier, the fabric supplier should be instructed to supply the shade grouping charts with roll number mentioned against each shade swatch. The garment buyers also should be informed clearly that for large volume orders that require fabric processing in more than one batch, there would be small batch to batch variation in properties.
5) Fabric with a special surface finish like peach finish, micro-sanding, etc. needs special care. Firstly, the supplier must be instructed to roll such fabric with face inside and put arrow marks on each piece showing the direction of such finish with clear arrow marks at both ends. This is to avoid massive shade variation due to stitching pieces finished in different directions, together.
7) Last but not the least, place orders with fabric manufacturers of reputation. Giving 10 cents more to a responsible and reputed manufacturer may prove to save lot of costs and penalties going forward. Failing to supply garments on time also badly affects the reputation which is priceless. The products of reputed companies also give better realization, lesser wastage and higher efficiency at garment making process.
At the end of the day, we should keep in mind that real prosperity does not mean only buying cheap and selling high to earn short term profit. The apparel manufacturing company that focuses on delivering quality, punctuality, communication and value to each customer will never have any shortage of business and riches in the long run.