Category: Garments

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Costing Sheet of Garments Manufacturing

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Costing Sheet of Garments Manufacturing

Woven Garments Costing Sheet: Do necessary costing before taking Garments orders because costing very important work for garments merchandising. This article has three types of garments costing, include all trims and accessories costing and fabrics costing. Here costing given per pcs wise and dozen wise for your easy understanding. Hopefully, after seeing this you will have a good idea of costing sheet of garments manufacturing.

Costing Sheet of Garments Manufacturing

Costing Sheet of kids Trouser

Costing Sheet of Kids Trouser
FABRICS DETAILS: 73% cotton, 25% poly, 2% elastane denim 7.5 oZ (YR-1923/3)
Sl No. Particulars COST SHEET FOR PER PCS+DZN
YY/YDS PRICE/YDS COST/PCS COST IN DZN
1 Self Fabric 1.2 $1.85 $2.22 $26.64
Total Fabrics Cost- $2.22 $26.64
Basic Trims
2 Pocketing 0.15 $0.70 $0.11 $1.26
3 Interlining $0.03 $0.36
4 Metal Zipper $0.12 $1.44
5 Plastic Button $0.02 $0.24
6 Metal button $0.04 $0.48
7 Metal Rivet $0.05 $0.60
8 Thread $0.08 $0.96
9 Hole elastic $0.06 $0.72
10 String with plastic tipping  $                 –
11 Special label EF, Yigga girls+SIZE WOVEN $0.03 $0.36
12 WASH CARE LABEL (LEFT SS INSIDE) $0.03 $0.36
13 WASH CARE LABEL (UNDER WCL1) $0.03 $0.36
14 HANG TAG EF, Yigga girls $0.04 $0.48
15 PRICE STICKER $0.01 $0.12
16 Waist tag (double) $0.08 $0.96
17 EMBROIDERY $0.10 $1.20
18 String $0.03 $0.36
19 Poly $0.08 $0.96
20 Carton $0.07 $0.84
21 Carto STKR,Tagpin,Gumtape $0.06 $0.72
Total- $1.07 $12.78
Embroidery/Print  $                 –
Total-  $                     –  $                 –
Wash  TOWEL BEACH WITH/PP $0.75 $9.00
Total- $0.75 $9.00
ALL FABRICS+TRIMS COST $4.04
Commercial Cost $0.08 $0.97
CM $1.35 $16.20
Total- $1.35 $16.20
EXTRA- $0.03
FINAL FOB: $5.50 $65.90

Costing Sheet of Skinny Fit Denim Pants

Costing Sheet of Skinny Fit Denim Pants
DATE : 1-Jan-19 SIZE RANGE : 38-50
BUYER : ORD/QTY : 5500 pcs
STYLE/REF NO : UNIT PRICE : $8.00
P.O. NO : TOTAL VALUE : $44,000.00
ITEM DESC  : SKINNY fit DENIM DELIVERY DATE  :  
SL ITEM PARTICULARS QTY DZ U/PIECE TOTAL  
COST/DZ
FABRIC 66% cotton 32% POLY 2% Lycra. Cuttable Width:53″(Shrinkage:L-4%, W-16%) 15.75 YDS  $ 2.51 $ $39.53
Pocketing Sheeting pocketing WHITE + BLACK 4.8 YDS  $ 0.9 $ $4.32
INTERLINING TC INTERLINING 2.2 YDS  $ 0.1 $ $0.22
TOTAL COST OF FABRIC $ $44.07
TOTAL ACCESSORIES 1 dz  $ 15.26  $ 15.26
 WASH COST (tei, whisker, hands and, pp, ) 1 dz  $ 7  $ 7
PRINT COST 1 dz  $ 3  $ 3
EMB COST 1 dz  $ 1.5  $ 1.5
 $  $ 70.83
CUTTING & MAKING  ( CM ) COST 1 dz  $ 18  $ 18
 $  $ 88.83
COMM  COST 1 dz  $ 2.12  $ 2.12
COMMISION 1 dz  $ 1  $ 1
company profit 1 dz  $ 4  $ 4
FOB PER DOZEN 1 dz  $  $ 95.96
PRICE PER PC 1 pcs  $  $ 8 12
1 pcs  $  $ 8 FOB $ PCS
TOTAL ACCESSORIES DETAILS COST
Wash Care label 1.05 DZ  $ 0.12 $ 0.13
Care label 1.05 DZ  $ 0.08 $ 0.08
 Label 1.05 DZ  $ 0.7 $ 0.74
Antitheft 1.05 DZ  $ 0.6 $ 0.63
Back Pocket card 1.05 DZ  $ 0.4 $ 0.42
TAPE 8 YDS  $ 0.1 $ 0.8
Waist Tag 1.05 DZ  $ 0.25 $ 0.26
HANG TAG-1 1.05 DZ  $ 0.5 $ 0.53
HANG TAG-2 1.05 DZ  $ 0.5 $ 0.53
Patch 1.05 DZ  $ 0.7 $ 0.74
Barcode sticker poly 1.05 DZ  $ 0.3 $ 0.32
Sticker tag 1.05 dz  $ 0.2 $ 0.21
Zipper 1.05 dz  $ 1.5 $ 1.58
Button 0.09 grs  $ 6.2 $ 0.56
Rivet 0.55 grs  $ 2.1 $ 1.16
tissue paper 1.05 dzn  $ 1 $ 1.05
POLY BAG BLISTER 1.05 DZ  $ 0.3 0.32
POLY BAG PE 10mm 1.05 DZ  $ 1.6 $ 1.68
THREAD 20/4 – 1500 mtr 0.7 con  $ 0.8 $ 0.56
40/2 0.75 con  $ 0.72 $ 0.54
20/2 – 3000mtr 0.65 con  $ 0.78 $ 0.51
GUM TAPE 1.05 ROL 0.5 $ 0.53
SCOTCH TAPE ROL $
TAG PIN BOX $
Shipping mark 1.05 PC  $ 0.06 $ 0.06
CARTON 7 PLY 1.05 PC  $ 1.3 $ 1.37
COST OF TRIMS/ACCESSORIES $ 15.26

Costing Sheet of Skinny Fit Denim Pant

Costing Sheet of 5 Pockets Long Pant

Costing Sheet of 5 Pockets Long Pant
DATE : 1-Jan-19 SIZE RANGE : 44-58
BUYER : ORD/QTY : 9500 pcs
STYLE/REF NO : UNIT PRICE :
P.O. NO : TOTAL VALUE :  $                                  –
ITEM DESC : 5 PKT LONG DELIVERY DATE : TBA
SL ITEM PARTICULARS QTY DZ U/PIECE TOTAL  
COST/DZ
FABRIC 98% Cotton 2% Spandex,2/1 “S” Twill, Non-Peach Finish. Cons: 30x3Gr40D/170×80 Width: 5l”/52” 21.2 YDS  $ 2.38 $ $50.46
Pocketing Sheeting pocketing (White) 4 YDS  $ 0.75 $ $3.00
INTERLINING TC INTERLINING 2 YDS  $ 0.1 $ $0.20
TOTAL COST OF FABRIC $ $53.66
TOTAL ACCESSORIES 1 dz  $ 15.66  $ 15.66
 WASH COST (ENZYME WASH WITH SILICONE) 1 dz  $ 2  $ 2
PRINT COST 1 dz  $  $ 0
EMB COST 1 dz  $  $ 0
 $  $ 71.31
CUTTING & MAKING  ( CM ) COST 1 dz  $ 15  $ 15
 $  $ 86.31
COMM  COST 1 dz  $ 1.07  $ 1.07
COMMISSION 1 dz  $  $ 0
company profit 1 dz  $ 5  $ 5
FOB PER DOZEN 1 dz  $  $ 92.38
PRICE PER PC 1 pcs  $  $ 7.7 12
1 pcs  $  $ 7.7 FOB $ PCS
TOTAL ACCESSORIES DETAILS COST
Wash Care label 1.05 DZ  $ 0.1 $ 0.11
Care label 1.05 DZ  $ 0.1 $ 0.11
Satin Label 1.05 DZ  $ 0.1 $ 0.11
Sccurity Label 1.05 DZ  $ 0.8 $ 0.84
Main Label,Size Label, Fit Label, Brand Label Loop Label 1.05 DZ  $ 0.75 $ 0.79
Twill Tape 1.05 DZ  $ 0.66 $ 0.69
Pocket Flasher 1.05 DZ  $ 0.36 $ 0.38
Waist Tag 1.05 DZ  $ 0.55 $ 0.58
HANG TAG-1 1.05 DZ  $ 0.7 $ 0.74
HANG TAG-2 1.05 DZ  $ 0.7 $ 0.74
Disclimar Tag 1.05 DZ  $ 0.55 $ 0.58
Patch 1.05 DZ  $ 2 $ 2.1
Barcode sticker poly 1.05 DZ  $ 0.2 $ 0.21
Sticker tag 1.05 dz  $ 0.15 $ 0.16
Zipper 1.05 dz  $ 1.4 $ 1.47
Button 0.08 grs  $ 6 $ 0.48
Rivet 0.18 grs  $ 2.5 $ 0.45
tissue paper 1.05 dzn  $ 0.65 $ 0.68
POLY BAG BLISTER 1.05 DZ  $ 0.3 0.32
POLY BAG PE 10mm 1.05 DZ  $ 0.65 $ 0.68
THREAD 20/4 – 1500 mtr 0.75 con  $ 0.76 $ 0.57
40/2 0.75 con  $ 0.63 $ 0.47
20/2 – 3000mtr 0.65 con  $ 0.73 $ 0.47
GUM TAPE 1.05 ROL 0.6 $ 0.63
SCOTCH TAPE ROL $
TAG PIN BOX $
Shipping mark 1.05 PC  $ 0.06 $ 0.06
CARTON 7 PLY 1.05 PC  $ 1.2 $ 1.26
COST OF TRIMS/ACCESSORIES $ 15.66

Costing Sheet of 5 Pockets Long Pant

Download excel Sheet of Garments Costing Sheet

This content also refers below information

  • Costing of Woven Garments
  • Costing of woven bottom Garments
  • Costing of woven trouser
  • Costing of basic 5 pkts long pant
  • Costing of Ladies skinny denim pant
  • Clothing manufacturer cost sheet
  • Garments costing
  • How to make costing sheet of woven garments?

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

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Quality Flow Chart, Layout and Organogram of Garments

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Quality Flow Chart, Layout and Organogram of Garments

This content will give you an overall idea of garments quality controlling flow chart, Quality control layout and Quality management Organogram for Quality management system in the apparel industry. Hopefully, these would add value to your knowledge of Quality Flow Chart, Layout and Organogram of Garments.

Quality Assurance Flow Chart of the Apparel Industry

Flow Chart is a branch of data where operation list show sequence wise to understand what the process will set after a process. Generally, we make two kinds of garment products in the apparel industry, one is the top item another is the bottom item. The working flow chart is very different from every garments item.

Sewing Quality Check Procedure for Top Garments

Sewing Quality Check Procedure for Top Garments

Finishing Process Flow Chart for Top Garments

Finishing Process Flow Chart for Top Garments

Sewing Quality Check Procedure for Bottom Garments

Sewing Quality check Procedure for Bottom Garments

Finishing Process Flow Chart for Bottom Garments

Finishing Process Flow Chart for Bottom Garments

Garments Management Quality Organogram

Garment quality control organogram is a diagram that shows the structure of a garments factory quality department and how the various positions are related to each other, frequently used to show the chain of command and relative ranking of various positions in this department and include information such as the job titles, names, areas of responsibility for the employees and sorted out from top to bottom position. Here an organogram is given in below.

Garment Quality Management Organogram

Garments Management Quality Organogram

Garments Quality Inspection Layout with Manpower

Garments factory have long working flow of quality control to assure the quality of a garment product, many quality checkpoints and staff with responsibilities.  I have added every quality inspection points sequence wise to understand clearly and section wise quality management organogram. Hope this content will help all of you about a different quality process of a garments factory. In this article, I added a quality controlling Layout of every section of garments with required manpower list.

Section Wise Quality Control Layout

  1. A layout of fabrics quality inspection
  2. A layout of cutting quality inspection
  3. A layout of sewing quality inspection
  4. A layout of Finishing Quality Inspection

The Layout of Fabrics Quality Inspection

Layout of Fabrics Quality Inspection

The Layout of Cutting Quality Inspection

Layout of Cutting Quality Inspection

The Layout of Sewing Quality Inspection

Layout of Sewing Quality Inspection

The Layout of Finishing Quality Inspection

Layout of Finishing Quality Inspection

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

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Garments Quality Check Points and Their Quality Control

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Garments Quality Check Points and Their Quality Control

Garments QC/QA Check Points: There are four sections of garments quality controlling process, these can generate defects in manufacturing, sections are cutting, sewing, washing and finishing, and must be there some criteria check QC team for garments product quality. This article clearly showing quality controlling criteria of every quality checkpoints of a garments factory and simply described garments quality requirement. Hopefully, after reading this you will have a good idea of Garments Quality Check Points and Their Quality Control.

Garments Quality Check Points and Their Quality Control

 Section wise Garments Quality Check Points

  1. Cutting quality Check Points
  2. Sewing Quality Check Points
  3. Washing Quality Check Points
  4. Finishing Quality Check Points

Garments Quality Check Points and their Checking Criteria

Here given section wise quality checkpoint description for your better understanding as mentioned every work of garments quality control department.

Cutting Process Quality Check Point

  1. Fabric upside down: Make sure the fabric is not upside down.
  2. Fabric Skewing: A maximum skewing of 2 cm for the chest of 60 cm is acceptable, but not more. This defect can be solved by re-setting of the fabric at the fabric mill.
  3. Relaxation: Before cutting, knitted, elasticized woven fabrics should be suitably relaxed for around 12~24 hours or more, depending on the type of fabric. Relaxation is mandatory for stretch fabrics.
  4. The height of cutting pile: The higher the pile on the cutting table, the more chance the cut pieces are unequal in size. This can lead to size specification & fitting problems. Make sure the height is suitable for the type of fabric (usually 2~3 inches and never more than 5 inches).
  5. Numbering and bundling: Make sure the different parts are properly numbered to avoid shading and that this numbering can be easily removed after sewing is complete.
  6. Storing: Make sure the different parts are properly stored, for example, rolled, and not folded.

Sewing Process Quality Check Point

  1. Critical operations: Check all critical operations repeatedly (like the sewing of the neck- seam, armhole, cuff, placket etc.), so the operator gets the clear input of what is required and how to make it correctly before large quantities of garments are finished.
  2. Attaching label should be correct as per the size of 100% garments
  3. Checking bonding strength of interlining in the fusing process.
  4. Seam allowance:  check operators repeatedly on this point to make sure they use the correct seam allowance.
  5. Numbering: Make sure the sewing operatives keep parts with the same number together to avoid shading.
  6. Confirm Garments styling construction and measurement is correct as per approved sample.

Washing Process Quality Check Point

  1. Washing method: normal wash, stone wash, sand wash or enzyme wash.
  2. Bleaching method: stone bleach, garment bleach
  3. Any special process. E.g. over-dye after the washing process
  4. The color tone of the blue yarn
  5. The whiteness of the white yarn
  6. Resultant color tone: bluer or yellowish
  7. Rubbing effect: contrast on the blue yarn and white yarn
  8. Evenness on the blue and white parts
  9. Hand-feel
  10. Record the identification of the sealed sample, quality standards on the final inspection report to ensure QC check the bulk according to the correct standards.
  11. Tick and sign all quality standards as an indication of proper QC checking.
  12. QC should not release the shipment if they find the following major faults.
  13. Color out of the approved shade band
  14. Fabric flaws and washing marks in excess of 1″ on the garment zone above the knee
  15. Fabric flaws and washing marks in excess of 3″ on any part of the garment

Finishing Process Quality Check Point

  1. Button attaching and button
  2. Pressing
  3. Full Garments quality check
  4. Packing and carton

Button Attaching and Button

  • Snap button too loose / too strong
  • Snap button not closing properly / broken
  • Missing poly washer for snap buttons
  • Button coming off
  • Fabric not strong enough to hold the button
  • Mark from molding
  • Paint damaged
  • Rust
  • Text on button not straight
  • Wrong position / not in line with counterpart / incorrect spacing
  • Button shank missing when required
  • Buttonhole too big or too small
  • Buttonhole not clean / badly stitched/ losing shape / stitched with wrong thread quality
  • Spare button missing or put in the wrong position

Check Pressing

  • Shiny marks
  • Not pressed or improperly pressed
  • Should avoid the press and fold the pigment dyed fabrics before garment washing entirely. It is because it will leave a clearly visible mark on the garment after washing. After sewing, put the garments on a hanger until washing starts.

Full Garments Quality Check

  • Checking full garments workmanship defects
  • Measure 100% garments to assure fittings
  • Heat seal peeling off
  • Confirmation quality check of final garments product

Packing and Carton Quality Check

  • Correct ticketing and placement
  • Packing accuracy of quantity, assortment, and folding
  • Correct carton selection as per customer requirement
  • Packaging, sealing, binding and barcode checking

Final Inspection Quality Check Points

After completing carton, Garments buyer QC does a Final quality inspection, evaluate final product quality. Final Audit or inspection is the most important factor for a garments factory. Final Audit is the final judgment of product quality from the buyer, the inspection calibrates overall garments factory quality controlling. Without passing final inspection, garments cannot be shipped. A final inspection report is the quality certificate from garments buyer what give a certificate of a factory about their finished product quality that allows or reject to ship garments. There are specific quality checking points of a finished garments final audit, here I have given these in below.

Quality Inspection Criteria’s are of Final Audit

  1. Workmanship
  2. Appearance
  3. Measurement/Fittings
  4. Materials
  5. Accessories
  6. Finishing/Packing

Workmanship

  • Fusing
  • Open seam
  • Broken stitch
  • Miss/Skip Stitch
  • Mending
  • Seam grinning
  • SPI incorrect
  • Needle damage/cut/holes
  • Puckering/Twisting
  • Stripes/Plaid Mismatching
  • Stepping or Hi-low
  • Misaligned/Insecure Buttons
  • Crooked stitching
  • Raw edge
  • Looseness/Knots
  • Buttonhole
  • Incorrect tension
  • Main Label open/slanted
  • Contrast thread visible
  • Loop slanted

Appearance

  • Loose/uncut thread
  • Dirt mark
  • Oil stain
  • Garment damp
  • Crushed
  • Pressing
  • Shinning
  • Wrinkle

Measurement/Fittings

  • Out of tolerance any measurement points

Materials

  • Body fabric way
  • Contrast fabric
  • Print/Dyeing Fault
  • Color Shading
  • Bald Patches
  • Holes or Cuts
  • Yarn Runs
  • Slubs
  • Color fly/ Foreign yarn

Accessories

  • Thread/ Yarn
  • Main Label
  • Care Label
  • Zipper
  • Tapping/Capping
  • Screen print/Embroidery
  • Buttons/Snaps/Rivets
  • Velcro
  • Elastic

Finishing/Packing

  • Assortment
  • Carton Marks
  • Polybag printing
  • Hangtag
  • Price ticket
  • Barcode
  • Carton Barcode

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Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

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Job Responsibilities and Report of Production Planning Department in Garments

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Job Responsibilities and Report of Production Planning Department in Garments

PPC in Apparel Industry: PPC stands for production planning and control, planning for capacity utilization and on time raw material input, output and delivery. It helps a factory to utilize the resource allocation of activities, supply chain, materials, and production. A garments production planner plays a key role in Garments production, does line plan and execute planning. Here in this article, you will get detail ideas of Job Responsibilities and Report of Production Planning Department in Garments.

The Job Description of a Production Planner in the Apparel Industry

  1. Responsible to monitor and evaluate raw materials, manpower planning, production recording and follow up
  2. Production planning according to capacity and 100% capacity utilization in minimum cost.
  3. Setting production target and archive on time.
  4. Follow up sampling, pre-production activities, cutting, sewing, washing, and finishing according to plan.
  5. Update production planning time to time according to the current situation.
  6. Work to implement planning and reduce plan vs actual gap.
  7. Distribute production planning to all related production staff and meeting to implement planning.
  8. Monitor daily production; make daily production report and tracking section wise production.
  9. Achieve on time shipment maintaining production work sequence.
  10. Work with merchandising team to QC file as per production lead time and monitor trims-accessories and fabrics in-house status.
  11. Closely monitoring all pre-production activities(Size set cutting, PP meeting, Pilot Run) and priority-based work progressing.
  12. Chase finishing team for on-time final arrangement and ship the goods.
  13. Implement production planning and update time to time.

The Job Description of a Production Planner in the Apparel Industry

We have another article you may like: Production Planning and Control in the Apparel Industry

Planning Reports in Garments

Production planning department or planner has to send a planning report to mid and Top management. Here I am giving a planning report to understand how to make production planning report. Section wise production planning report is given in the below.

Line Wise Production Planning Report in Garments

Sewing Line Production Planning Report
Order No Input Date Planned Capacity / Day / Line No of Lines Name of line Working Hour/Day Production Unit Weekend / Holidays during prod No of Working Day Required Output Finish Date
8257873 7-Nov 800 1 2-C 10 MCL 2 8 17-Nov-18
825784 30-Oct 850 1 2-A 10 MCL 1 8 8-Nov-18
8257875 27-Oct 950 1 2-E 10 MCL 3 20 19-Nov-18

Report of Sewing Line Production Planning

Washing
Order No Wash Input Date Planned Capacity Per Day Production Unit No of Working Day Required Wash Will Complete
8257873 10-Nov-18 10000 MCL Laundry Ltd 9 20-Nov
8257874 8-Nov-18 10000 MCL Laundry Ltd 2 11-Nov
8257875 30-Oct-18 10000 MCL Laundry Ltd 19 21-Nov

Job responsibilities and Report of Production planning Department in Garments

Goods Finish To Final Audit
Order No Goods Finish Start Date Planned Capacity Per Day Weekend/Holiday during prod No of Working Day Required Goods Will Ready for Audit
8257873 3-Nov-18 10000 2 12 17-Nov-18
8257874 12-Nov-18 10000 1 7 20-Nov-18
8257875 11-Nov-18 10000 1 8 20-Nov-18
Plan Summary
Factory Wise Planned Production Capacity Sewing No Of line /Prod Unit Factory Wise Planned Production Capacity Wash A quantity of Dry Process / Normal Wash
12000 10 15000 NOT APPLICABLE
10500 10 15000 NOT APPLICABLE
9500 10 12000 NOT APPLICABLE

Line Plan of Garments

Line Plan of Garments
QTY Shipment CRD Input date Sample Cutting status Cutting Input Cut status Sew line SAM Manpower Efficiency W/HR PRO/DAY Sewing Status SEW COM Fin Status S.trm Acc Inspection V-Code Shp Swatch Blanket Shd band F.trmAccss Occurrence Remarks
229 2/15/2017 15-Jan Fit & PS 243 243 30.03 2 42 750 70% 11 7920 243 1 − 31 Ok Pass Ok Ok Ok Ok In Sewing Running
623 2/15/2017 15-Jan Fit & PS 654 654 30.08 2 42 750 70% 11 7920 456 1 − 31 Ok Pass Ok Ok Ok Ok In Sewing Running
209 2/15/2017 15-Jan Fit & PS 226 226 30.03 2 42 750 70% 11 7920 15 1 − 31 Ok Pass Ok Ok Ok Ok In
227 2/15/2017 15-Jan Fit & PS 248 248 30.03 2 42 750 70% 11 7920 15 1 − 31 Ok Pass Ok Ok Ok Ok In
151 2/15/2017 15-Jan Fit & PS 173 173 30.02 2 42 750 70% 11 7920 173 1 − 31 151 Ok Pass Ok Ok Ok Ok In Finishing Running
73 2/15/2017 15-Jan Fit & PS 91 91 30.01 2 42 750 70% 11 7920 91 1 − 31 73 Ok Pass Ok Ok Ok Ok In Finishing Running
4,000 2/15/2017 16-Jan Fit & PS 4122 4122 29.53 2 42 750 70% 11 7920 3489 2 − 1 Ok Pass Ok Ok Ok Ok In Sewing Running
2,312 2/15/2017 10-Jan Fit & PS 2325 2325 35.30 2 42 750 70% 11 7920 2325 1 − 26 2293 Ok Pass Ok Ok Ok Ok In Finishing Running
3,000 2/15/2017 16-Jan Fit & PS 3093 3093 29.39 2 42 750 70% 11 7920 3093 2 − 1 3050 Ok Pass Ok Ok Ok Ok In Finishing Running
2,300 2/15/2017 16-Jan Fit & PS 2416 2416 29.30 2 42 750 70% 11 7920 2416 2 − 1 2156 Ok Pass Ok Ok Ok Ok In Finishing Running
2,000 2/15/2017 16-Jan Fit & PS 2032 2032 29.26 2 42 750 70% 11 7920 2032 2 − 1 2001 Ok Pass Ok Ok Ok Ok In Finishing Running
3,000 2/15/2017 16-Jan Fit & PS 3089 3089 29.39 2 42 750 70% 11 7920 3089 2 − 1 2618 Ok Pass Ok Ok Ok Ok In Finishing Running
3,500 2/15/2017 16-Jan Fit & PS 3675 3675 29.46 2 42 750 70% 11 7920 3675 2 − 1 Ok Pass Ok Ok Ok Ok In Sewing Running

Garments Production Planning Related Interview Questions and Answers

  1. Who are the production planners in Apparel industry?

Production planners a person who does production planning in garments as per buyer order. His works started after getting confirmed order.

  1. How to do a production plan in a garments factory?

By distributing garments order to every line targeting on time delivery for production based on factory production capacity, using planning software, ERP or spreadsheet (Excel).

  1. How to execute garments production planning?

By making sure all necessary items for production in housed, completing all pre-production activities are primary steps execute production planning.

  1. Why need to do production planning in the apparel industry?

To give on time garments delivery to the customer (buyer), need to do accurate production planning in the apparel industry.

  1. How to implement production planning in a garments factory?

Ensuring effective planning and work accordingly.

  1. How to do a production planning report?

By excel production planning and production, the report can be done easily.

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

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Duties and Job Responsibilities of Garments Buying House Technician

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Duties and Job Responsibilities of Garments Buying House Technician

Buying House Technical Team: A buying house technician is a person, who is responsible to evaluate/review all types sample, make comments and approve or reject all types of the sample from buyer end. The person is also responsible for sample quality, works to improve sample and bulk quality, guide factory to improve quality. A buying house technical team consists of technicians where they know all types of Technical thing of a Garments factory. Here in this article, you will have detail idea of Duties and Job Responsibilities of Garments Buying House Technician. In a job description, all the duties and responsibilities are clearly disclosed.

Duties and Job Responsibilities of Garments Buying House Technician, Job Description of Garments Buying House Technician

Job Description of a Buying House Technician

  1. Evaluate all types of sample: Development, Proto, Fit, Size set, Jump size set, Seal, Buyer ref, etc. with a feasibility study of product & risk analysis. Timely identifying & resolving mass production impracticalities.
  2. Handle sample inspection and sample approval by reviewing construction, measurements, patterns, workmanship, garments outlook presentation, fitting (dummy and model), on fit sample and size set
  3. Recommend the process simplification & cost saving alternative options to the buyer
  4. Sealing of pre-production sample & handover style file for mass production.
  5. Provide buyer and factory QA advice on complex product items to factories before & during the manufacturing process.
  6. Participate in PP meeting, review pilot run, and monitor mass production for complex product and new vendor.
  7. Perform special assignment and case study for continuous improvement in quality & productivity.
  8. Assist maker technicians, QA for checking patterns, specifications & construction, and plan on quality according to company standards and requirements.
  9. Provide technical & quality control seminars & workshop for the vendor’s knowledge & skill improvement.
  10. Providing training, technical support for the vendor to implement E- pattern approval process.
  11. Perform an investigation to the customer claim case to find out a solution to minimize the repetition of the problem
  12. Provide required training/guidelines to garments maker to update/enhance their skills on technical, quality and operational capabilities.
  13. Provide technical support to Merchandising, Design Team, factories, overseas designers and vendors.
  14. Quality improving work of different sewing operation and implement in factory sewing line.
  15. Develop process quality and advice factory to follow.
  16. Responsible for all technical issue of garments.

Jobs in Buying House Technical Team

 Generally, we can find the following types of designation in buying house technical department.

  • Assistant Technician
  • Technician
  • Senior Technician
  • Assistant Technical Manager
  • Technical Manager

Duties and Job Responsibilities of Garments Buying House Technician pdf

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A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

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Sewing Machine Operator Recruitment, Grading and Skill Matrix

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Sewing Machine Operator Recruitment

Sewing operator recruitment is a tough job in the apparel industry. To recruit the best quality and efficient operator, sewing operators have to stitch one, two or three bundle garments with good seam quality by a certain time, recruiter checks his/ her production capacity and product quality and can be seen how many operations an operator can do, these few criteria set his grading. Then, Grade, wise operator salary is fixed by sewing operator recruiter, garments manufacturer have own operator grade wise salary standard. Here in this article, you will have details idea of Sewing Machine Operator Recruitment, Grading and Skill Matrix.

Sewing Machine Operator Recruitment, Grading and Skill Matrix in Garments

Related articles you may like:

  1. The job description of a sewing operator
  2. List of the sewing machine used in garments
  3. Different parts of a sewing machine

Sewing Operator Grading

Lots of factors have to consider when doing operator grading. First, we have to know what type of operation operator does, then the operator’s production efficiency and many others factor. Here you can see below information on how to grade sewing operator.

Sewing Operator Grading

SN. Operation Name M/C Type
“A” Grade Category
1 Pocket Attach SN
2 Placket Attach SN
3 Collar Attach SN
4 Collar Close SN
5 Zipper Join SN
6 Zipper Top Stitch SN
7 Placket Box Make SN
8 Neck Join OL
9 Sleeve Join OL
10 Side Seam OL
11 Bottom Join OL
12 Nk Piping  FL
13 Bottom Hem FL
14 Waist Band T /S Kansai
“B” Grade Category
1 Placket 1/16 Top Stitch SN
2 Bk Nk T/S (LBL T/S) SN
3 Back Rise Join OL
4 Front Rise Join OL
5 Shoulder Join OL
6 Front Nk T/S FL
7 Bk Nk Binding FL
8 Sleeve Hem FL
9 Arm Hole T/S FL
10 Shoulder Join OL
“C” Grade Category
1 Collar Tack SN
2 Side Vent Tack SN
3 Sleeve Inside tack SN
4 Sleeve Out Side Tack SN
5 BTN Hole BH
6 BTN Stitch BS
7 Bar Tack BT

Here,

  • SN – Single needle sewing machine
  • OL  -Overlock sewing machine
  • FL – Flat lock sewing machine
  • BH – Buttonhole sewing machine
  • BS – Button stitch sewing machine
  • BT – Bartack sewing machine

Explanation of Sewing Machine Operator Grading

  • For the each A grade operation giving 10 marks for 100% efficiency level up to a maximum of 8 operations, marks will be multiplying by the efficiency Percentage. (Example: 10X 0.7, if the efficiency level 70%.)
  • For each B grade operation giving 7 marks for 100% efficiency level up to a maximum of 8 operations, marks will be multiplying by the efficiency Percentage. (Example: 7X 0.7, if the efficiency level 70 %.)
  • For each C grade operation giving 5 marks for 100% efficiency level up to a maximum of 8 operations, marks will be multiplying by the efficiency Percentage. (Example: 5 X 0.7, if the efficiency level 70 %.)

General Grading of Sewing Machine Operator

  1. 10 marks will be given if the absenteeism less than 3%
  2. 5 Marks will be given for over one-year service in the factory
  3. 1 to 10 Marks will be given for types in satisfaction level of production management.
  4. To be an ‘A’ grade operators must have the ability to operate 3 different machine
  5. To be a ‘B’ grade operators, must have the ability to operate 3 different machine

Final Grading Based Marks of Sewing Machine Operator

  • 80> GRADE A
  • 70 > 80 GRADE B
  • 60 > 70 GRADE C

Sewing Operator Skills Matrix

Sewing operator skill matrix or summary is a database of operator production capacity of different operation, number of machine and operation with the name he can operate, these process efficiency, salary, date of join. The database makes in Excel (spreadsheet), keeping by IE department in the apparel industry. This database help factory to migrate operator to another operation, to find out best sewing operator easily, to do operator grading easily.

Sewing Machine Operator Recruitment, Grading and Skill Matrix

Sewing Operator Skill Summary List

  1. Number of operation can sew
  2. Number of sewing machine can operate
  3. Production capacity per operation
  4. Sewing efficiency
  5. Servicing period in factory
  6. Seam quality

Sewing Machine Operator Recruitment, Grading and Skill Matrix in Garments pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

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Garments Test Requirements of Buyer

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Garments Test Requirements of Buyer

To ensure consumer product safety, wearability, garments quality, strength and others requirement of buyer, garments test is done as a buyer requirement. The test is conducted in full garments form not in fabrics form, safety is very much important for children garments. The garments test is done in buyer laboratory or in third-party laboratories or any nominated laboratories. The main objective of garments is to check consumer right and safety of a product, which is ensured by the test report. Garments test report is mandatory for every garments lot, without passing it shipment is not allowed. The cost of a test depends on the type of test you are asking. Garments testing criteria may little bit vary buyer to buyer but it is a mandatory requirement for all garments manufacturer. So as a garments maker you need to be careful about all garments test requirements of buyer otherwise you may lose your valuable customer. Another thing is, a good quality control system may give you the right product.

Garments Test Requirements of Buyer

List of Test Required for Garments

For your better understanding, I made a list of test normally required for garments which are asked by the garments buyers.

  1. Fiber content
  2. Care instruction
  3. Dimensional Stability To Home Laundering
  4. Distortion After Washing
  5. Appearance After 3 Washes
  6. Fabric Weight
  7. Tensile Strength
  8. Tear Strength
  9. Seam Strength / Slippage
  10. Color Fastness To Crocking
  11. Color Fastness To Ozone
  12. pH Value
  13. Dimensional Stability To Home Laundering
  14. Distortion After Washing
  15. Appearance After Washing
  16. Falling-Pendulum Type (Digital Elmendorf) Tester
  17. Colorfastness To Crocking
  18. Colorfastness To Ozone
  19. pH of The Water-Extract from Wet Processed Textiles
  20. Restricted substance list
  21. Sharp materials

Hopefully, this information will be helpful, If you need any detail information then please let me know. I will try to give your required information.

Garments test requirement of Buyer pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

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Fabrics Testing Requirements for Garments

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Fabrics Testing Requirements for Garments

Fabrics Lab Testing: Fabrics need to pass through some testing for its quality, strength because by cut and sewing fabrics become garments, fabrics lab testing is very much important. Buyer has the requirement to pass the fabrics lab test report before allowing fabrics for garments manufacturing. Here you can find detail idea of fabrics testing requirements for garments, standard testing method and buyer required performance of every testing criterion, this would help you to know about all in-house fabrics testing and its standard testing method.

Fabrics Testing Requirements for Garments

Where does Fabrics Lab Test need?

  • Fabrics after dying, before delivery to garments
  • Fabrics before cutting, inspection stage of in garments manufacturing

List of Lab Testing Need to be Done of Fabrics

  1. Dimensional stability/Shrinkage to Laundering/washing
  2. Skew Test
  3. Distortion Test
  4. Dimensional stability to Dry Cleaning
  5. Appearance Rating
  6. Colorfastness to Laundering
  7. Colorfastness to Crocking
  8. Colorfastness to Perspiration
  9. Colorfastness to Water
  10. Colorfastness to Light
  11. Tensile strength
  12. Seam slippage
  13. Seam strength
  14. Tear strength
  15. Bursting strength
  16. Pilling resistance
  17. Fiber content
  18. Fabric weight (g/m2)
  19. Formaldehyde content
  20. Lead content (scrapable surfaces only; children only)
  21. Azoic Dyes

Fabrics Lab Testing Requirements and Standard Test Method

Fabrics Lab Testing Requirements and Standard Test Method

SL No Test Description Standard Test Method Performance Requirements
1 Dimensional stability/Shrinkage to Laundering/washing AATCC 135/150 Woven fabrics: +/- 3% max. Knitted fabrics: +/- 5% max.
2 Skew Test ASTM D3882  No skew
3 Distortion Test AATCC 179 Tolerance +/- 3%
4 Dimensional stability to Dry Cleaning AATCC 158 Woven fabrics: +/- 3% max. Knitted fabrics: +/- 3% max.
5 Appearance Rating Visual/AATCC 179, Method 2 Satisfactory, including no shape distortion, no cross staining and skewing 3% max for woven and 5% max for knits.
6 Colorfastness to Laundering AATCC 61 Color change: 4,  Color staining: 3, Self-staining: 4.5
7 Colorfastness to Crocking AATCC 8 Dry: 4, Wet: 3
8 Colorfastness to Perspiration AATCC 15 Color change: 4, Color staining: 3
9 Colorfastness to Water AATCC 107 Color change: 4, Color staining: 3
10 Colorfastness to Light AATCC 16 20-hour test: 3.5
11 Tensile strength ASTM D5034 Blouse: 25 lbs Shirt/dress/skirt/pyjamas/lining: 30 lbs Outerwear: 37 lbs Trousers/shorts/overall/pocketing: 50 lbs
12 Seam slippage ASTM D434 Blouse/shirt/dress/skirt:  15 lbs Pyjamas/lining: 18 lbs Outerwear/pocketing:  22 lbs Trousers/shorts/overall:  25 lbs
13 Seam strength ASTM D1683 Blouse/shirt/dress/skirt:  22 lbs Pyjamas/lining: 25 lbs Outerwear/pocketing:  30 lbs Trousers/shorts/overall:  37 lbs
14 Tear strength ASTM 1424 Blouse: 1.5 lbs Pyjamas/lining: 1.8 lbs Shirt/dress/skirt/outerwear: 2.0 lbs Trousers/shorts/overall/pocketing: 2.5 lbs
15 Bursting strength ASTM D3786 Fabric: 40 lbs /sq. inch, Seam: 35 lbs /sq. inch,
16 Pilling resistance ASTM 3512, – 30 minutes 3.5
17 Fiber content AATCC 20/20A +/- 3% tolerance for blends; No tolerance for single fiber
18 Fabric weight (g/m2) ASTM D3776 +/- 5% of specification
19 Formaldehyde content JIS L 1041 Garments with contact to skin < 75 ppm, Other garments < 300 ppm
20 Lead content (scrapable surfaces only; children only) 16 CFR 1500.3 < 600 ppm
21 Azoic Dyes Zero tolerance

Fabrics Testing Requirements for Garments pdf

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A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

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Garments Quality SOP

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Garments Quality SOP

Garments quality SOP is the standard operating procedure for quality control in Garments manufacturing. Setting Standard procedure for garments is very much important to get up to the mark of readymade garments. In a garments quality SOP, a clear description for every working system and requirement to get the best possible result is written. Following SOP, we can do any work in a standard way and know what to do to complete the whole operation. Garments buyer also gives SOP for handling their order. It is makers responsibility to follow while making their garments. Every garments factory has own SOP for every process they are involved with. Basically, a garments quality SOP is the written guidelines of standard procedure to do a particular work for making garments. Time to time standard process may change because garments involve with making different garments different times. Actually, a good standard operating procedure increases productivity by reducing the system loss or operating losses. In a garments factory a quality control department is responsible for ensuring the best quality of garments, so they always follow a standard process for monitoring and controlling process and products.

Garments Quality SOP, Garments Quality Standard Operating Procedure

List of SOP Needed for Garments Quality

Listed SOP hyperlinked with needed SOP, you can read by clicking.

  1. Fabrics inspection SOP
  2. Shade band procedure
  3. Fabrics process before cutting
  4. Trim and accessories inspection SOP
  5. Garments pattern making SOP
  6. Fabrics relaxation, spreading and cutting procedure SOP
  7. Sewing quality procedure
  8. Garments measurement SOP
  9. Needle controlling SOP
  10. Sharp edge controlling SOP
  11. Button pull test SOP
  12. Button pinch setting SOP
  13. Metal detection SOP
  14. Mold prevention SOP
  15. Finishing SOP
  16. Quality control manual or SOP

If you need any SOP for a specific process/ task related with quality or you want to develop a quality manual or any technical thing of garments manufacturing, please feel free to contact with me through sending mail to the following address.

Garments quality SOP pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

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Garments Quality Control Procedure

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Garments Quality: Every garment buyer have own quality manual or procedure, a standard quality procedure should maintain in garments manufacturing industry to reach up to the mark in quality control. Every person related to apparel manufacturing need to know about garments quality procedures, especially for them who work in the quality department. Here I wrote all general garments quality control procedure of Garments manufacturing from cutting to finishing that’s how we do to maintain quality procedures.

Garments Quality Control Procedure

Garments Quality Control Procedure

  1. Checking fabrics, trims, and accessories as per buyer requirement.
  2. Make size set sample and review in PP meeting
  3. Pattern correction based on size set garments measurement
  4. Cut 300 pcs as a pilot run from all size range after PP meeting to ensure all size measurement is correct then proceed to cut for bulk.
  5. Keep pattern library of a printed pattern in the CAD room
  6. If fabrics shrinkage differs more than 2 %, a different pattern will be made
  7. Ensuring that fabric with accessories as per consumption okay to proceed bulk then start cutting
  8. Cutting will be started after buyer QC approval of bulk cutting
  9. Ensure all cut panels should be double check with pattern & maintain your record as per SOP
  10. All cut panels to be quality inspected before inputting to sewing section.
  11. Checking fabrics bonding strength with interlining after fusing, fusing attached temperature record with thermal paper.
  12. Keeping Go by sample for every running style to confirm garments styling is accurate as per sample.
  13. Ensure all marking instrument should be invisible especially pen & chalk mark pencil use light mark but it should be erased able daily basis, follow up oil leakage from the machine by put blotting paper or fabric under the pressure foot, also double check all the machine inside have any extra needle by the magnet.
  14. Ensure all machine tension with feed rock set up properly  by our actual fabric quality on daily basis & keep a record with mock-up
  15. Needle control and Needle change record maintain properly.
  16. 100% garments quality inspection in both sewing and finishing
  17. 100% garments to be measured in finishing
  18. Button pull test checking and record daily
  19. Garments pass through metal detector machine
  20. Keep packing accuracy as per buyer approval, check daily and take buyer approval for folding and packing

Garments Quality Control Procedure pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam