Pilot Run Process in Garments Industry

A pilot run is a precautionary manufacturing process of Garments manufacturing after PP meeting and before starting bulk production. Pilot run is also called as Trial run in Garments manufacturing, generally done in bigger lot (3000+ quantity), manufacturer cut 200-250 pcs for pilot run. Pilot run was done in bigger quantity than size set.

Pilot Run Process in Garments Industry

The main purpose of the pilot run is to fix garments measurement within the tolerance limit. After passing PP sample, Garments manufactures go for a pilot run to ensure Measurement and Garments construction correction is okay, most of the time pilot run sample also has measurement deviation, so pattern adjustment is applied for bulk. If the Pilot run cannot be passing to the buyer, bulk cutting cannot start, buyer procedure doing pilot before bulk.

Pilot Run Process in Garments Industry

Why Need to do Pilot Run Before Bulk Production

  1. To avoid mistake risk of bigger Garments lot
  2. To check measurement after correction on the PP sample pattern to ensure bulk garments accurate measurement
  3. To check Garments sewing quality, ensure successful removal of size set sample defects
  4. To set sewing line and smooth production for bulk
  5. Starting production in small portions to minimize error.

Pilot Run Meeting Activities

  • Checking pattern, adjustment history, and review
  • The pilot run meeting generally coordinate by concern buyer QC or Factory quality head
  • Review Pilot Run sample and compare quality with approved sample
  • Checking measurement and compare improvement with PP sample
  • Taking all precautions for bulk production
  • Risk Analysis of all critical operations
  • Checking washing appearances, shade with approved standard, hand feel

Pilot Run Meeting Checklist

  1. Approved Sample
  2. QA Style File
  3. PO Sheet
  4. Production PDM/Bulk PDM, Styling Check with Updated PDM & seal sample, Check the specification
  5. Before Wash Spec by CAD
  6. Approved sample Comments
  7. Approved Trim Cards, Trims Placement check with updated PDM
  8. All Sewing Trims Approval
  9. Body Fabric (Approved Dye Lot)
  10. Embellishment Approval(EMB/Print/Rhinestone)
  11. Approved Wash Standard/V-Code
  12. Shade band- Leg Panel
  13. Shade Blanket
  14. Shade Card
  15. Shrinkage Test Report
  16. Distortion Test Report
  17. Tube Test/ Cross Stain Checking Blanket
  18. Button/ Rivet Pull Test Report & mockup
  19. Home Laundry for Heat Seal LBL/Button/Care LBL/Leather Patch/Rhinestone
  20. TNA
  21. Fabric & Trims Inventory Report
  22. Fabric & Trims Inspection Report
  23. Vendor’s Internal PP Meeting & Evaluation Report
  24. Pattern checking, Change Log
  25. Washing T- (Tint) Heavy or less, (abrasion) Less or heavy (coverage all dry process), H- (Hand feel) Hard or soft
  26. Match Number UPC and care label each piece
  27. Waist Closer buttons check
  28. Security Tack each piece
  29. Check Zipper slider open & close
  30. All hardware
  31. ATF button & Elastic Pull & check both sides.
  32. Belt tack stitches both end & weaving quality & belt size.
  33. The belt tracking number should be the same all the pieces
  34. Check inside pocket, remove stone, dust, long thread.
  35. Hanger, sizer check with size label After attached
Pilot Run Process in Garments Industry

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