PRODUCTION PROCESS FLOW
Factory starts working on an order after order is confirmed. In the following production processes are listed and explained.
#1. Fabric Sourcing
Factory sources fabrics from buyer recommended fabric suppliers. This way they able to maintain the quality level of the fabrics. The fabric is sourced and stored in the fabric store in racks. Fabric inspection is done prior to issue fabric to cutting department.
#2. Trims Sourcing
Factory sources trims and accessories based on requirement and stored in Trim store room. Trims are kept buyer wise. For inventory management factory uses bin card. Each bin card contains details of trims, available inventory stocks.
#3. Cutting
Factory uses CAD marker for marker making. Factory initially cut one lay for production pilot run. Once Pilot production run is approved by customer representative they go for bulk cutting.
Based on style requirement, cutting of garment component are done two ways such as fixed cutting and block cutting. Factory uses computerized cutting machine, straight knife machine and band knife cutting machine.
#4. Sewing
Line supervisors and Industrial Engineers do line setting based on line layout prepared by IE. First operator in the line picked up bundle or lay from the trolley depending on operation. Bundles are moved from one operator to another after completion of operations. One important point I want to mention here that factory does not have extra manpower for thread cutting. So, thread cutting is done by sewing operators.
#5. Paper Transfer Printing
Most of the orders required a Brand logo. Instead of screen printing factory prefers transfer printing method for logo printing and this transfer printing is done in the line.
#6. Print and embroidery Checking
Printed and Embroidery panels are checked for print and embroidery quality and stored for sorting based on the sequence number of each layer.
#7. Re-cutting
Re-cutting is done for block panels after printing or embroidery process to shape components. Re-cutting is done in single panel or couple of panels.
#8. Super market
Numbering and bundling of cut components are done and bundles are kept on trolleys. Trolleys are placed in a supermarket, a place where all trolleys are kept and marked line number to which line a trolley to be sent.
#9. Loading
Factory has multiple lines in a floor and lines are designed (machine layout) product specific. Trolleys with cutting are loaded to the line as per plan.
#10. Sewing
Line supervisors and Industrial Engineers do line setting based on line layout prepared by IE. First operator in the line picked up bundle or lay from the trolley depending on operation. Bundles are moved from one operator to another after completion of operations. One important point I want to mention here that factory does not have extra manpower for thread cutting. So, thread cutting is done by sewing operators.
#11. Paper Transfer Printing
Most of the orders required a Brand logo. Instead of screen printing factory prefers transfer printing method for logo printing and this transfer printing is done in the line.
