When I associate an apparel product with sportswear brands, I feel something special in that garment. So I was very much excited to see a sportswear manufacturing company. Fortunately, I got a chance to visit one that makes garments for sportswear brands such as Adidas, Reebok, Nike and Puma to name a few. Product range includes Crewneck Tee, Polo, Sweatshirt, Fleece Jacket, Pants etc.
From the discussion with a production head, I learned a lot of about production processes, product details, and production process flow. The manager also emphasizes whatever recent changes they had done to improve factory performance in terms of labour productivity.
Most of the orders do not require garment washing.
The production system of the factory is really very good. They set sewing lines such a way that finishing tasks such as pressing, packing, tagging and carton making is done in the line. This line is called assembly line with online finishing. They don’t have separate finishing department. Each floor have department from cutting to packing of goods.
I had worked more than two years in knits factory. I found that production processes of this factory are almost similar to other knits factories. However, it will be very interesting to know - why sportswear manufacturing companies are different? How sportswear manufacturers make its goods and supplies to Brands?
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| Sportswear Brands |
Most of the orders do not require garment washing.
The production system of the factory is really very good. They set sewing lines such a way that finishing tasks such as pressing, packing, tagging and carton making is done in the line. This line is called assembly line with online finishing. They don’t have separate finishing department. Each floor have department from cutting to packing of goods.
I had worked more than two years in knits factory. I found that production processes of this factory are almost similar to other knits factories. However, it will be very interesting to know - why sportswear manufacturing companies are different? How sportswear manufacturers make its goods and supplies to Brands?
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. PP Sample Development
The pre-production sample is made in the production line and is sent to the customer for approval. Factory makes PP sample in production line instead of sampling department, where most companies make PP sample from sampling department.#4. PP Meeting:
PP meeting is held after approval of PP sample. In PP meeting it is discussed that how an order factory will process.#5. Cut panel laundry (CPL)
This process is carried out to improve the dimensional stability of the knitted fabric, such as fabric shrinkage and torque or twisting that may happen after garment wash. All fabrics do not require to CPL process. Factory does fabric shrinkage test and spirality test in in-house lab. Based on the lab test, they decide whether to do CPL or not.
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.
Fixed cutting – In case excess fabric at seam lines does not required for following processes such as printing and embroidery fixed cutting is done.
Block cutting is done for printing and embroidery process for some designs. In some cases, block cutting is required for few component and rest components are cut fixed shape in same lays.
All components are numbered with sticker or marker and stored. Numbering is done to ensure that garment components are attached from same layer and size.
#6. 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.
Fixed cutting – In case excess fabric at seam lines does not required for following processes such as printing and embroidery fixed cutting is done.
Block cutting is done for printing and embroidery process for some designs. In some cases, block cutting is required for few component and rest components are cut fixed shape in same lays.
All components are numbered with sticker or marker and stored. Numbering is done to ensure that garment components are attached from same layer and size.