Pre-Production Processes in Garments Manufacturing
The Pre-Production process is the sum of the total process that is done before bulk starting, there are many tasks and procedures that have to be completed by the manufacturer before going to production. Production preparation processes are important for any manufacturing company. This article is on the Production preparation process of the garment industry.
Pre-Production Process of Garment Manufacturing
Garments manufacturing is all about cutting, sewing, and finishing but there is a list of complex tasks in the pre-production stage as garments production preparatory process, especially on fabric quality inspection and pre-production sampling. Without getting these processes done, bulk production cannot be started as per the buyer’s QC procedure. All fabrics quality procedures and sampling are very much sensitive, garments maker needs to be careful of smooth production and keep needed input flow to sewing. If a factory cannot perform pre-production activities properly, the factory may fall down in productivity. Generally, it takes at least 12-13 days to go for bulk production after receiving fabrics from the supplier. The production planning team directly follows up on these pre-production activities.
Flow chart of Garments Pre-production processes
| Process | Action if the process fails |
| Fabrics procedure | |
| Fabric in-house | |
| Fabric inspection completion | If you cannot pass, ask the supplier for compensation or fabric replacement |
| CSV/ SSV checking | |
| Status on CSV/SSV | If you cannot pass, ask the supplier for compensation or fabric replacement |
| Shrinkage & Distortion | |
| Status on shrinkage & distortion | If you cannot pass, ask the supplier for compensation or fabric replacement |
| Blanket set complete | |
| Status on blanket | If cannot pass, ask the supplier for compensation or fabrics replacement |
| Pre-production sampling | |
| Trim card or QC file and sample approval | If the Trim card is not approved, the size set cannot be cut |
| If pass above all, then start size set cutting | |
| Size set approval with a pattern adjustment | If PP meeting fails, maker ask to recut size set sample |
| A pilot run cutting (If need) | |
| Pilot Run approval | |
| Bulk cutting | |
Fabric Quality Procedure
We cannot cut fabrics without going through some fabric quality inspection procedures by a certain time after receiving from the supplier, these are the fabric’s visual defects, shading, shrinkage, and distortion. If fabrics fail to meet one of those quality checkpoints, the garment maker has to claim by buying a house and ask for fabric replacement. Sometimes, fabric suppliers come to verify garment makers’ claims so it takes if there are any quality issues (short quantity/ width shipment) in fabrics; most of the time it takes more time to solve problematic fabric issues.
Pre-production Sampling
After completing all fabrics procedures garments maker has to cut the size set sample (also known as PP sample) to do a pre-production meeting. If the PP sample cannot pass, the factory has to remake the PP sample again. Then garments maker cut the pilot run and complete the sewing and finishing process. After completing the pilot run process, the garments manufacturer allowed for bulk production.
Pre-Production activities operation Flow chart of Garments Manufacturing:
Preparation for the PP Meeting:
Inform all departments to prepare for the PP Meeting:
Master File.
Approved Fabric & Trim Swatch.
Fabric & Trim Availability Report.
Production Plan.
Line Layout & Manpower Allocation.
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Size-Set Sample Preparation:
This sample shall be done with the involvement of Line In-Charge, Line Supervisor, Line Q.C, Work-Study Officer, Mechanic, and Technical/Sample Room. Shall follow buyer’s Sample, Comments, and Operational break down prepared by Work-Study officer.
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Critical Operation Identification:
During Size-Set Sample/Line Sample development, Production, Quality, IE Staff and Mechanic together shall do this study and identify all critical points at the construction of a garment.
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PP Meeting (Internal & Buyer):
To discuss and take necessary Corrective & Preventive Actions before starting production of each style and to make sure every department is updated with the Fabric/Accessory Requirement, Technical Specifications, Testing Requirements, Workmanship, Target, Shipment Details, etc.
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Approval for Pilot Cut:
To proceed with the pilot cut prior to going for Bulk Cutting.
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First Production Analysis:
To compare the Initial Output (Finished Goods) of the Pilot Run against the Buyers’ approved Sample/Standard prior to going for Bulk Cutting
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Finalizing Pattern for Bulk Cutting:
To verify and make sure to use the correct pattern for the Bulk Cutting.
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Approval for Bulk Cutting:
To assure and certify that all Pre-Production activities have been completed prior to starting Bulk Cutting of each style.
Pre-production processes are the key thing for quality control in garment manufacturing. Here manufacturer can do measurement control and process capability analysis.