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Production Processes and Quality Assurance

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Based on in-store replenishment. Seasonal and staple good demand is easier to forecast. ... Unit production system (UPS) Garment parts fed on over head ... – PowerPoint PPT presentation

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Title: Production Processes and Quality Assurance


1
Production Processes and Quality Assurance
2
What and Why
  • Production
  • The construction process by which pattern pieces,
    materials, and trims are merged into a finished
    apparel product.
  • Cost of production
  • Affected by product design and pattern
  • Affected by the process
  • Designers and pattern makers need production
    knowledge

3
Manufacturing Environments
  • Mass production
  • Short-cycle production
  • Mass customization
  • Which one depends on
  • Product type
  • Replenishment strategy

4
Mass production
  • Very large quantities
  • Economies of scale
  • Staple products
  • Low fashion risk
  • Based on in-store replenishment
  • Seasonal and staple good demand is easier to
    forecast.

5
  • Allows for longer lead times
  • Can source off-shore and save on labor
  • Mexico and CB

6
Short-cycle Production
  • Producst produced closer to time of market demand
  • High fashion goods
  • Short selling seasons (6-8 weeks)
  • No intention of in-store replenishment
  • Asia
  • Fabric availability
  • Skill levels

7
Mass Customization
  • Short cycle manufacturing to an individual
    consumer
  • All the newest technologies
  • Body scanning
  • Pattern alteration software
  • Virtual try-on
  • Ink jet fabric printing

8
  • Involves the customization of fit, design and
    personalization
  • Product already designed
  • Customer customizes the product
  • Fit customization
  • Difference between the standard and the customers
    needed adjustments
  • Body scanning

9
  • Design customization
  • Fabric
  • Sleeve
  • Color
  • Personalization
  • More than just initial

10
  • Advantages
  • Reducing inventories
  • Minimizing returns
  • Reducing distribution costs
  • Customer relations
  • Brand loyalty
  • Consumer research

11
Production Sewing Systems
  • Single-handed
  • Samples and prototypes
  • Couture
  • Progressive Bundle
  • Common
  • Bundles rolled from one machine to another
  • Piece rate pay
  • High level of WIP
  • Bottle necks with varying speeds

12
  • Unit production system (UPS)
  • Garment parts fed on over head conveyors
  • One garment at a time
  • Cross training
  • Reduced operator handling time
  • Equipment investment

13
  • Flexible Manufacturing Systems (FM)
  • Modular manufacturing
  • Self directed work teams
  • Entire garments
  • Paid on quantity and quality

14
  • Factors
  • Downtime very critical
  • Investment in training
  • Support from management
  • Cultural change
  • Employees need to think and perform differently
  • Increase in quality
  • Reduction of WIP

15
  • Agile manufacturing
  • Uses all the newest technologies
  • Mass customization
  • Flexibility in process
  • Combination of systems

16
Developments
  • Faster industrial machines
  • Specialized machines
  • Standup sewing
  • Equipment maintenance is critical
  • Noise and air pollution
  • Computerized sewing machines
  • robotics

17
CAD/CAM
  • Computer aided manufacturing
  • Increase speed and accuracy of
  • Pattern making
  • Market making
  • Grading
  • Cutting sewing

18
  • Improved product quality
  • Reduced production time
  • Diversified product line

19
CIM
  • Computerized Integrated Manufacturing
  • Everything is linked
  • Smooth flow of information
  • Linkages to CAD/CAM
  • Costing efficiencies
  • Spec sheet development
  • Numerically controlled stitching machines

20
Production Process
  • Determine the process that is most efficient and
    cost effective
  • Construction specifications
  • Sewing sequence
  • Fusing interfacing
  • Applying embellishment
  • Pressing
  • Hang tags
  • Folding
  • Packaging

21
  • Considerations
  • Equipment capabilities
  • Labor costs
  • Subcontracting
  • What can be done prior to sewing process?
  • Problems
  • Procurement of materials
  • Fabric, zippers
  • Subcontractors
  • International sourcing issues

22
Finishing
  • Pressing and packaging
  • Adding labels and bar codes
  • Floor ready merchandise
  • RFIC
  • Radio frequency ID chip
  • Fabric
  • Laundering
  • Stonewash
  • Pre shrink
  • Garment dyed

23
Quality Assurance
  • Meets the standards
  • ASTM and AATCC
  • Adhere to spec sheets
  • Fabric inspection
  • On-grain
  • Dye lots

24
  • Sewing and finishing
  • Stitches
  • Seams
  • Edges
  • Button holes
  • Hems
  • Plaid matching

25
  • Finishing
  • Thread trimming
  • Closure placement
  • Shoulder pads
  • Linings
  • Pressing

26
  • What if they dont meet standards
  • Refuse shipment
  • May not be able to replace
  • Stock outs
  • Seconds in outlet stores

27
Logistics Agents
  • Export agent
  • Assists with exporting product out of contracted
    country
  • Freight forwarding company
  • Move goods from country of production into the US
  • Customer broker
  • Help with customs
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