Jacket production process flow chart

Jacket production process: Production of jacket or any other garment has to face several process from Order receiving to shipment.Production Process flow chart help to understand jacket manufacturing method through which types of raw material get converted into wearable garment.

Production process start as below.


Jacket manufacturing process can categorizes into four man divisions 

1. Cutting
2. Stitching
3. Finishing
4. Packing

1. Cutting:- Once the pp sample got approved from customer then bulk production process starts by cutting the fabric and other trims like linings, pocketing and interlinings as per req. after cutting there are some process to be follow  in cutting dept before releasing the panels for sewing section.Panel fusing is a crucial part of jacket cutting division because there are types of fusing used in jacket and heat temperature should be as per interlining nature.
See below the cutting process flow chart.



2. Stitching or sewing:-Through sewing section- No and types of panels get converted into ready garment. There are Several types of sewing machines used for making a jacket or garment as per there design construction requirement.
See below the production process flow chart of sewing section. 







3. Finishing:- Finishing section is playing very important role in jacket manufacturing through pressing types.For jacket pressing there are types of pressing or blocking  machines req to give a proper visual look. Individual parts are pressed through individual machine.after finishing only a garment can get wearable.
See below the production process flow chart of finishing section.



4. Packing:- Packing section looking after size wise ratio packing as well tagging,bar-coding,polybag insertion and carton packing or hanging.
See below the production process flow chart of packing section.


Garment get ready for dispatch after packing.

Various department of jacket or garment manufacturing organisation

Garment manufacturer industries and there departments:- Industry where fabric get converted into wearable ready made garments and packed to dispatch it for sailing. Garment industry can categories into various departments where every dept have there own importance as per there functions.

Below is the list of all department and sub dept with there function. 

1. Design dept:This dept deals with-Creation of new artwork or sketch for garment or convention for the construction of a garment.

Sampling Dept: Construction of samples as per design artwork and specifications selected by design team. Maintaining quality stander of product as well taking care of smoothness of operations to help better productivity of organisation. 

2. Marketing and sales dept: Marketing and sales team responsible for Identifying, anticipating and satisfying customer requirements profitably.This team Play most important role in garment or any other industries as order gaining and companies profit depends on this dept.
Merchandising dept: Sub dept of marketing and sales. Merchandising team deals with product. Responsibility start from offering samples with  there targeted price to customer,order receiving till dispatch of goods as well follow up for payment receiving from customer, reporting to market head in order to project statement sowing profit or loss and growth or break down of business through OCR(Order closing report) and FCR(Final closing report).

3. Planning dept:This dept helps to build strong relationship with other dept in order to obtain maximum output and product timely delivery to customer as per committed dates. 
4. Commercial dept: Identification and development of business opportunities and profitable product or project management from inception to completion is main responsibility of this dept. There are various sub dept of this management..
Finance dept:- Dealing with funds or money in terms of cash or credit arrangement,planning,procuring and controlling of all financial resources to help organisation  achieving goal of the company.
Account dept: Account dept measures the results of an organisation's economic activities and conveys this information to verity of users as per require.
Purchase dept:Purchasing management dealing with raw material procurement from external source through market research for better quality in lower price and on time material inward as per lead time of product requirement.Taking care of supplier dealing in terms of providing product information,negotiation of price, purchase contract, supply agreement, arrangement of payment as per payment terms agreed,Transportation arrangement for inward of goods in warehouse,corrective action against supplier for there negligence.
Store dept: Store management taking care of the accountability of raw material as well final product in terms of material inward, material storage and issue or dispatch of material by maintaining there record to share with various related users.

Import and Export dept:Importation and exportation is the action of buying and selling the product or services from another country under jurisdiction of government rules as per trade agreement between both countries and taxation applied for the product.

5. Administration dept: Administrative management act to direct people towards accomplishing a goal.

6. Human resource (HR) dept:-Hr dept manage the human capital of an organisation and focus on implementing  policies and process In terms of recruitment, employee-relations,organising training programs,social activity arrangements, deals with concerns of employee as per companies policies such like- Health, harassment or discrimination, etc.

8. Production Dept: Conversion of fabric into ready made garment till there packing through various operations and techniques is the role of this dept.Playing most important role for the organisation in terms of production efficiency or deficiency.  

There are various sub dept of production dept in garment industries as below.

Cutting Dept: Panel cutting from fabric to make garment with the help of pattern which is generated by pattern maker or cad , Panel fusing, Panel bundling and stickering done to maintain shading issue within garment.

Embroidery and printing dept: Done on panels as per design artworks and size before stitching or after stitching as per production friendly.  

Stitching dept:Panel attachment or assembling to prepare a wearable garment through various operations.

Finishing dept:Finishing of garment refer to process involve in making garment wearable as per desired look by various methods like- Thread trimming,washing or dying,Button attachment, pressing,etc 

Washing or Dying: Process where ready garment get washed or dyed as per fabric required treatment by various process.

Packing Dept: Refers to the Process where ready garments after finishing will get accessorised with tag or any special accessories,bar coding, folding, garment inserted into poly bag, carton packing and taking to ware house for dispatch with carton stickering or shipping mark.   

8. IE Dept: Deals with optimisation of complex process , systems or organisations,development,improvement and implementation of integrated systems to help achieving better productivity and quality product.

9. Quality dept:Run through the set of procedures intended to ensure manufactured product or services adheres to define set of quality criteria to meet the customer or client requirement. 
There are separate quality team working for each individual production's sub departments to ensure the process flow in right direction as per require.  

10.Maintenance dept: Team of engineers applying engineering concepts for optimisation of equipment,procedures and departmental budgets to achieve better maintainability, reliability, and availability of equipment or machinery for operations. 
11. IT Dept or EDP dept: Deals with computer and other electronics devices optimisation in terms to better maintainability,reliability and availability of devices.    
12.Utility dept:Deals with basic requirement and services of organisation.

Garment cost break down sheet detailing

How to make Garment cost break down  sheet- Costing sheet is prepared by associating all cost which is directly or indirectly involve in product making by keeping profit margin in it.It contains material cost + Material cost finance charges + special requirement + Labour cost + Overhead cost + freight cost + margin + agencies commission if any.

See below costing format to understand step by step details of cost sheet to make it perfectly.

Product projection: Projection qty is the main point of costing sheet, cost of product can be adjustable as per qty. Ex- More qty = less coated labour price where as Less qty= Higher labour cost.
On top of thre sheet you can see the approx qty(projection qty) is mention.

Product detail:- Detailing about the product is also req to verify cost sheet when authorised by higher authority from the section as this sheet is prepared by merchandising team who has the responsibility of business growth.

Material cost:- This is the main part of cost sheet, Raw material cost is depend upon the selection of trims quality. price should be taken as per trims quality or else it might result direct loss to the company.

Finance charges:Finance charges is applicable as per lead time of raw material cost payed to supplier  which return by final product payment through customer. It cover the interest on money which invested to purchase the materials.

Special Requirement:- Cost which paid to outsource process. Ex- Embroidery, Printing, washing,Dyeing, etc.

Testing: Material testing report is mostly require by customer. This cost depends upon no of testing as per there rate.

Labour cost:- It's depend upon the SAM value of product.

Overhead:- Over head cost is depend upon the structure of manufacturer staff members as well other allowance which involve in making product.

Freight Charges: Transportation cost of final product dispatch as per shipment terms.

Margin: Profit percentage of total cost.

Agency commission:- If order taken through some agency then manufacturer have to pay the commission %  of total cost to agency.

Tax or Duty:- Applicable as per govt tax rules as per product quality.

Quoted Price:- Final price including all cost.

Authorisation:-Cost sheet is prepared by Merchant,AMM or MM. which should be re-verify by superiors of the team.

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Export garment sampling and there concern

Export garment sampling:- Sampling are playing vital role in  export garment manufacturing for all areas to Receive orders and what to produce after receiving the order.You can get types of sampling and there definition details on search but this article will help you knowing the correct sampling req and there importance in export garment division.

We can categories export garment sampling in three divisions as below :

1. Design or offer sample

2. Salesman sample

3. Production samples

Design or offer samples: Marketing team is dealing with this division sampling as they have to offer samples to customer as per marketing trend of there sailing country in terms of fabric and design to get the orders from customer. This categories samples named as : Development sample, Proto samples or offer sample etc.
There are separate designing dept mostly available in all reputed export houses, this team is taking care of design development section.Marketing or merchandising team is doing selection of fabric and design to be offered to buyers. See below the concerns involve while dealing with such kind of samples.

Concern: While making such kind of samples there are some points to be taken care for getting good result of it otherwise it wont be useful to make it.

a. Visual Look:- Selection of design for fabric and construction should  be as per taste of brand. for example: Formal category brand will not select casual or funky look.
b. New trend:- All brands try to offer new or upcoming fashion trends to there customer so always try to make some thing new design as per brand requirement.
c. Trims selection:- This is the most effective part in sampling, while doing selection of trims you should have to keep in mind the below things.

Price:- Trims price is the main part of selection category Like- If customer want the product in lower range category then the trims selection will be as per lowest price material where as higher range category product material should be in higher price range.
Colour:- Fabric colour and there contrast trims colour selection plays effective role for this sampling as these types of sample used for presentation. On the time of colour selection you should have to keep in mind the design requirement by co-ordination with design team to give the appealing look of a garment which give interaction to customer towards product.while dealing with it, put yourself as customer and think what kind of material you will choice on the time of garment purchasing.
Material type:- Garment trims are always available in different kind of material. So on the time of material quality selection you should have to keep in mind the buyer quality stander(every buyer has there own material quality stander).
d. Operation :- Manufacturing operations selection is depend upon garment manufacturer feasibility. You can offer your own method of stitching or other manufacturing Technics in these samples, if customer like that they will approve as it is or they can able to suggest there requirement.

2. Salesmen sample: Some export buyers req salesman sample to check product demand in market. They want to confirm there order qty by checking the market demand through salesman sample. they are ordering mass qty of sample from supplier to distribute it among stores and book there requirement as per demand.qty of these category samples can be -10 to 50 pcs or more as per req.

Concern:Bulk order qty depend upon these samples so some points to be taken care while making these samples.
Quality: Stitching quality and fitting of garment is playing important role in these samples as its directly involve to end customer.
Trims: Here also have to follow the trims selection as per design or development sample concern criteria only.
Packing: Packing should be done as per properly to visualise the product.
Lead time:Manufacturing lead time is very short for theses samples.If the sample will not reach on time in stores then the season might lapse which may cause bad result in order qty confirmation.

3. Production samples: After order confirmation there are lots of sampling req by buyers before production or after production, See below the production sample list with there concern.
Fit sample: Basically req to check the base pattern fitting as well to check the the stitching stander of a design.

PP sample:Can also called production go ahead sample as its made at with all actual trims as well considering comment on fit sample received from buyer for final sample.
Size set sample:Basically req to check all size garment spec before starting bulk cutting. If there any measurement issue in any size can able to control by making all size garment before starting the bulk order cutting.
Advertisement sample:Advertisement or photo shoot sample require for sales promotion. It can be offer from bulk which require before garments reach in stores.
Shipment sample:This is the reference sample for customer record about the product made from supplier.


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CBM and volume weight calculation for shipment booking

If you are related to garment industry, you should have to know about the cbm calculation  and volume weight calculation details to book your shipments with sea or air.

This article will help you to book your shipment by knowing the space requirement of your goods.

Sea shipment:

There are three size of container commonly used by garment manufacturer for sea shipment. 

20" Container

40" Normal container

40" High cube container

See below the average cbm capacity for each container.

20" Container- Max capacity-26 to 28 cbm.

40" Normal Container- Max capacity-55 to 58 cbm

40" High cube Container- Max capacity- 65-68 cbm.

How to calculate- You can use the simple formula for calculating cbm detail of your goods by knowing the length, width, height and no of cartons.

Simple Formula for CBM calculation - Length(cm) x Width(cm) x Height(cm) x No of cartons(pcs) / 1000000= Total cbm of your goods.

Example-Carton size- 65x45x20 cm.

                No of carton 400 pcs.

As per formula- 65x45x20x400/1000000=23.4 CBM(Require 20" container for 400 cartons).

Air shipment:

If you are dealing with air shipment then volume weight calculation information also req to book your shipment space in airways.

Kindly note:- Air shipment weight calculated by two methods

By Gross weight(Total carton weight) 

By Volume weight(Formula)

Higher weight always get to consider for payment rate/kg in air shipments.

Simple formula for Volume weight- Length(cm) x Width(cm) x Height(cm) x No of cartons(pcs) / 5000= Total volume weight of your goods.

Example- Carton size- 65x45x20 cm.

                No of carton 400 pcs.

                Gross weight per carton-10.2 kg

Total Volume weight = 65 x 45 x 20 x 400 / 5000 = 4680 kg (Volume weight)

 Total Gross weight = 10.2 x 400 = 4080 kg

In this shipment volume weight is higher then gross weight so per kg air ship cost applicable on volume weight which is 4680 kg.

Example:- Airways rate Rs 125/kg

so the total air cost will be - 125 x 4680= 585000/-

Jacket Interlinings and there importance in jacket manufacturing

Garment technical details info

Jacket Interlinings: Inner trims are playing main role towards the look of Jacket or blazer. Types of interlinings getting used in making jacket to give the proper visual look as per body shape.
If you are related to garment manufacturing then this article will help you to understood about the jacket interlining details and there importance while dealing with jacket or blazer quality issues.

Non woven fusing:- Non woven fusing used in jacket body part or lining part as per requirement to retain softness of fabric while stitching to avoid puckering issues, its also help to give garment shapes.

Types of non woven fusing used in jacket manufacturing as per there use in shape requirement of a jacket.

Micro dot fusing: Mostly used in all shaped(curve and straight folds) part to retain the fabric softness which will help in terms of crease marks as well in sewing.It can be used on parts like- Sleeve bottom fold,collar,lapel fold,armhole, front panel on cut pkt pkt flap etc.

Reinforcement fusing:Mostly used on folded parts which help to maintain length stretch issue by the wait of fabric.

Woven Fusing:- Woven fusing hold the fabric by there nature and give a clean visual impact looks to a jacket Mostly used in front facing part.

Under Collar Felt:- It helps to maintain the shape of color by its nature.its a type of non woven interlining.Thicker felt is first choice by manufacturer as its help to avoid fullness in collar without much care while sewing.

Chest Canvas: Harder, ruff and bouncy woven interlining material which gives the embossed shape to a jacket front part.jacket can be made with half canvas or full canvas as per customer and design requirement.Max bouncy canvas can give more visual impact of cleaning of shape. 

Chest felt:- Non woven thicker soft material Mainly used to cover the roughness of chest canvas piece and give the soft feel inside the garment as well enhancing the shape visual look.

Shoulder pad:- Important interlining which helps to give the shoulder slope shape in jacket or blazer or suit. Shoulder pad is made with various types of row materials. Selection of material depend on class of the jacket or suit. Thickness can be used as per shape of the pattern for shoulder.While choosing shoulder pad thickness take the help of pattern maker about slop depth of shoulder in pattern.

Sleeve head role:- Made with harder woven and softer non woven material. harder or bouncy material gives the shape and non woven material giving soft feel on sleeve armhole top part of a jacket.

Bridal Tape:- Its a woven stretchable fusible tape which mostly used on lapel fold parts stitched with canvas to give fullness on lapel fold to give proper folding fullness in fabric.Fullness requirement very by the pattern. it can be 3 to 8 mm as per req.

Armhole tape:- Stitched with armhole end fabric part to give proper fullness to fabric get properly fold without any puckering or fullness issue impact on front part of armhole.Fullness requirement can be deffer pattern by pattern.

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