CLOTHING MANUFACTURING STEPS
Konsey Textile is a custom clothing manufacturer in Turkey. In order to undestand of manufactuing process of clothing, we have listed garment manufacturing process from fabric to product. Please contact us for your all inquiries.
Design of Clothing Manufacturing Processes
In layman’s terms, design is a drawing on paper that will serve as a creative and imaginative form of the envisioned. As with any industrial product, the first step in the production of clothing is the design of the clothing. In the first stage of the clothing design, market research and economic analyses are done on the product about to be produced. In addition, the functional characteristics the product needs to have are determined. This information is combined with the technical knowledge necessary for the production of the clothing, thus resulting in the creation of the design of the clothing to be produced. This resulting design is expressed through line, color and texture.
Functionally and aesthetically inspired designs can be accepted or rejected during this stage. If rejected, the process that has taken place up to this stage is redone. If accepted, a prototype of the product (sample product) is prepared. The prototype prepared is examined and necessary corrections are done, and all operations to be performed on the product are determined and delivered to the production department during the entire production process such as the material list, molds, production methods, quality tolerances and cost calculations of the clothing.
Determining all the specifications of the product as well as all the details of the production process during the design process minimises the problems that can be encountered during production. For this reason, this phase is the most important stage of clothing production. In the ready-made clothing sector, the first production department where information technology is used is the design department. Computer aided design (CAD) systems, which have become increasingly popular in recent years, are a network that helps designers in businesses and provides a wide range of mobility capabilities.
It is possible to easily perform operations such as painting, coloring, and drawing adaptations on the computer screen and experimenting with various alternatives to increase the imagination so that more effective designs can be presented. This causes significant increase in the productivity and profitability of the business.
Functionally and aesthetically inspired designs can be accepted or rejected during this stage. If rejected, the process that has taken place up to this stage is redone. If accepted, a prototype of the product (sample product) is prepared. The prototype prepared is examined and necessary corrections are done, and all operations to be performed on the product are determined and delivered to the production department during the entire production process such as the material list, molds, production methods, quality tolerances and cost calculations of the clothing.
Determining all the specifications of the product as well as all the details of the production process during the design process minimises the problems that can be encountered during production. For this reason, this phase is the most important stage of clothing production. In the ready-made clothing sector, the first production department where information technology is used is the design department. Computer aided design (CAD) systems, which have become increasingly popular in recent years, are a network that helps designers in businesses and provides a wide range of mobility capabilities.
It is possible to easily perform operations such as painting, coloring, and drawing adaptations on the computer screen and experimenting with various alternatives to increase the imagination so that more effective designs can be presented. This causes significant increase in the productivity and profitability of the business.
Pattern Preparation
A pattern is something in clothing production that is created from paper cardboard or other similar materials which carries the dimensions, model and cutting characteristics of the clothing, is prepared separately for each body, and ensures that the fabric is cut correctly or helps in marking and trimming in the clothing’s production. One of the important procedures in ready-made clothing businesses is the preparation of the patterns of the clothing to be produced.
In the production of ready-made clothing, it is very important to prepare the pattern according to the target group’s size. Body size and proportions also form the basis of a correct clothing pattern. Standard measurements used in the preparation of product patterns in the clothing industry produced in Turkey do not match the sizes of the clothing, and thus the problems of clothing correctly fitting and providing desired clothing to the consumer are at the forefront. As a result, clothing produced in various sizes are found on the market. This is a standard that prevents high quality and low cost.
At this stage of clothing production, basic patterns of the clothing to be produced are prepared by taking advantage of standard measurements. During this stage, businesses can also benefit from the basic patterns already prepared. The model of the clothing to be produced is applied according to the prepared basic patterns. These pattern templates are made by giving it all necessary proportions and width and placing all text and symbols on them. This patterned template is usually a base pattern made from one of the size intervals. According to the type of clothing to be produced, the patterned template is enlarged or reduced according to the different sizes found on the size interval table. This process is called grading in ready-made clothing production.
The essence of grading is that the change from one size to another and the clothing’s adaptation to the pattern or patterns can happen without its model features changing or being distorted. There are three basic elements that must be fulfilled for this. These are the correct preparation of the measuring table, the use of the correct grading method, and the distribution of the amount of change between the sizes on the patterns.
In summary, at this stage, the preparation of the basic pattern necessary for the production of the clothing, the application of the patterned template, the template of the pattern and the process of laying out the necessary sizes are carried out. It is not possible to prepare a cutting layout before all the patterns are prepared.
In the production of ready-made clothing, it is very important to prepare the pattern according to the target group’s size. Body size and proportions also form the basis of a correct clothing pattern. Standard measurements used in the preparation of product patterns in the clothing industry produced in Turkey do not match the sizes of the clothing, and thus the problems of clothing correctly fitting and providing desired clothing to the consumer are at the forefront. As a result, clothing produced in various sizes are found on the market. This is a standard that prevents high quality and low cost.
At this stage of clothing production, basic patterns of the clothing to be produced are prepared by taking advantage of standard measurements. During this stage, businesses can also benefit from the basic patterns already prepared. The model of the clothing to be produced is applied according to the prepared basic patterns. These pattern templates are made by giving it all necessary proportions and width and placing all text and symbols on them. This patterned template is usually a base pattern made from one of the size intervals. According to the type of clothing to be produced, the patterned template is enlarged or reduced according to the different sizes found on the size interval table. This process is called grading in ready-made clothing production.
The essence of grading is that the change from one size to another and the clothing’s adaptation to the pattern or patterns can happen without its model features changing or being distorted. There are three basic elements that must be fulfilled for this. These are the correct preparation of the measuring table, the use of the correct grading method, and the distribution of the amount of change between the sizes on the patterns.
In summary, at this stage, the preparation of the basic pattern necessary for the production of the clothing, the application of the patterned template, the template of the pattern and the process of laying out the necessary sizes are carried out. It is not possible to prepare a cutting layout before all the patterns are prepared.
Preparation of Cutting Layout (Clothing Illustration)
In ready-made clothing production, after completion of the pattern preparation work, a layout of placement of the pattern parts in the fabric area of a certain width is required for the cutting operation. This process is called the cutting layout.
The preparation of cutting layouts is an important and demanding step due to the impact on cost. A small error in cutting layouts will cause all fabric layers to be cut incorrectly. While cutting layouts are being prepared, attention should be paid to the nature of the fabric, the width of the fabric, the length of the patterns, and the directions of the yarn, as well as the accumulation of all parts belonging to each size in the same region and economic placement. Cutting layouts can have different methods applied to them according to the properties of the fabric and their patterns. The purpose of preparing the cutting layout is to keep the rate of waste to a minimum. The rate of waste can be reduced by multi-size, long layouts. However, this should have an impact on cost and should be optimised for cutting layouts. Cutting layouts are prepared manually, as well as with computer aided design (CAD) systems, and this process can be prepared in a short time with minimum waste and error in a computer environment.
The preparation of cutting layouts is an important and demanding step due to the impact on cost. A small error in cutting layouts will cause all fabric layers to be cut incorrectly. While cutting layouts are being prepared, attention should be paid to the nature of the fabric, the width of the fabric, the length of the patterns, and the directions of the yarn, as well as the accumulation of all parts belonging to each size in the same region and economic placement. Cutting layouts can have different methods applied to them according to the properties of the fabric and their patterns. The purpose of preparing the cutting layout is to keep the rate of waste to a minimum. The rate of waste can be reduced by multi-size, long layouts. However, this should have an impact on cost and should be optimised for cutting layouts. Cutting layouts are prepared manually, as well as with computer aided design (CAD) systems, and this process can be prepared in a short time with minimum waste and error in a computer environment.
Layout
In the production of clothing, the layout of the fabric can be done through traditional methods, as well as through computerised systems in large businesses with higher capacity. When hand-made layouts are made, the fabric is cut from the top and the cutting is spread over the table according to the length of the predetermined cutting layout and its type. In these cases, bolts that can be rotated on the fabric can be used to automatically cut off the start and end points of the worker's platform for the extent of the cutting table, which will minimize the fatigue of the worker.
Be careful that the edge of the fabric needs to be parallel to the edge of the table when the process is done, but if there are minor differences in the width of the fabrics, it needs to be done from the widest to the narrowest.
In addition, the number or height of folds is determined according to the nature, capacity and texture of the cutting tools to be used in the cutting and the type and texture of the fabric. Placing too many layers of fabric so that they are not higher than the cutting blade to be used causes the layers of fabric to weld together, causing fumes to be produced during cutting and differences between the upper parts and the lower parts. After finishing the layout process, the cutting layout (cloth illustration) which had been previously prepared and set for the layout is to be placed on top. With this process, the fabrics are fixed with weights, long needles or tongs and prepared so that the fabrics do not slip and defects during cutting are reduced as much as possible . Layout processing can also be done with high-tech computerised systems.
With these systems, the layout process of the fabric can be done with minimal requirement and the desired quality can be done at high speed by automatically controlling the tension and the cutter head and end, automatically matching the squares and lines throughout the layout prepared on the computer. The prepared clothing can be compressed on vacuum tables preparing an appropriate environment for cutting.
Be careful that the edge of the fabric needs to be parallel to the edge of the table when the process is done, but if there are minor differences in the width of the fabrics, it needs to be done from the widest to the narrowest.
In addition, the number or height of folds is determined according to the nature, capacity and texture of the cutting tools to be used in the cutting and the type and texture of the fabric. Placing too many layers of fabric so that they are not higher than the cutting blade to be used causes the layers of fabric to weld together, causing fumes to be produced during cutting and differences between the upper parts and the lower parts. After finishing the layout process, the cutting layout (cloth illustration) which had been previously prepared and set for the layout is to be placed on top. With this process, the fabrics are fixed with weights, long needles or tongs and prepared so that the fabrics do not slip and defects during cutting are reduced as much as possible . Layout processing can also be done with high-tech computerised systems.
With these systems, the layout process of the fabric can be done with minimal requirement and the desired quality can be done at high speed by automatically controlling the tension and the cutter head and end, automatically matching the squares and lines throughout the layout prepared on the computer. The prepared clothing can be compressed on vacuum tables preparing an appropriate environment for cutting.
Cutting
Different cutting tools and motors can be used according to the characteristics of the parts to be cut according to the cutting layout (clothing illustration). The main ones are the sharp knife and round knife cutting tools. Of these tools, a sharp knife cutting tool is made up of a single sharp knife on a platform and an electric motor on top. When this cutter is used, it performs the cutting operation of the blade moving up and down with the aid of the electric motor. With this knife, definite turns can be made and mixed shapes cut. The round knife cutter carries out the cutting process with the help of a round knife rotating around its own axis with the help of the electric motor. It is not possible to make fine cuts with a round knife cutter; it can be used for cutting straight lines. Other than these, the other tool used in cutting called a bandsaw. With this tool, cuts are made by bringing the layers of fabric to a stationary cutter. In general, a bandsaw can used in the cutting of parts requiring precision as well as the collar, cuffs, pavers etc.
The most important thing to note during the cutting process is to make the cut at the top of the spreader and the bottom of the spreader the same as the lines shown in the layout. Cutting is an important process that requires attention in the production of clothing. Another important point to note for workers who do this in terms of work safety is to keep the cutting tool's cables and handles away from the blade of the cutting tool. For this reason, it is recommended that those who do the cuts use protective gloves. Cutting layouts prepared in a computer environment can be transferred to diskettes and prepared for cutting. These diskettes, which have been prepared, are loaded on to computer cutting machines. With a cutting head controlled by computers and able to move in various directions, a relatively high speed and less erroneous cutting operation can be performed as compared to manual cutting. Information such as which parts have been cut, where the cutting process is, the percentage of completion of the cutter, etc. can be viewed from the monitor during the cutting process. Using computerised systems for layout and cutting are more preferred for businesses that produce high-quality ready-made clothing due to cost.
The most important thing to note during the cutting process is to make the cut at the top of the spreader and the bottom of the spreader the same as the lines shown in the layout. Cutting is an important process that requires attention in the production of clothing. Another important point to note for workers who do this in terms of work safety is to keep the cutting tool's cables and handles away from the blade of the cutting tool. For this reason, it is recommended that those who do the cuts use protective gloves. Cutting layouts prepared in a computer environment can be transferred to diskettes and prepared for cutting. These diskettes, which have been prepared, are loaded on to computer cutting machines. With a cutting head controlled by computers and able to move in various directions, a relatively high speed and less erroneous cutting operation can be performed as compared to manual cutting. Information such as which parts have been cut, where the cutting process is, the percentage of completion of the cutter, etc. can be viewed from the monitor during the cutting process. Using computerised systems for layout and cutting are more preferred for businesses that produce high-quality ready-made clothing due to cost.
Preparation for Sewing
In this phase, which is referred to as preparation, the pieces of clothing are prepared for sewing. The first step in this process is the labelling of the parts that have been cut. The main purpose of labelling the pieces of clothing is to ensure that different sizes and fabrics of different colors are matched. For this reason, labels with size numbers, part numbers and other necessary information (model number etc.) are affixed with the aid of the numerator. These labels are affixed to the rear of the clothing pieces and to predetermined areas. Another point to note when labeling is the nature of the labels used. Labels should not come off when the piece of clothing is moved. At the same time, the adhesive parts should not leave permanent stains and marks on the fabric.
The second step in the preparation phase is to place the necessary markings on the pieces of clothing that are cut. These markings may include pocket locations, pleats, etc. Prepared marking templates according to sizes and marking pens and soaps can be used for placing these marks. Sometimes the necessary markings can be placed on pieces of clothing with punching tools and threading tools.
After getting the necessary markings on the pieces of clothing, the pairing of the pieces begins. During this stage, pieces of clothing are mapped according to the size numbers and piece numbers of the models. Another preliminary preparation made before sewing is the process of fixing. During this stage, the necessary clothing is fastened with suitable presses and irons. Also, if embroidery is used as a decoration or a brand, embroidery processes are usually performed during the sewing preparation stage.
The second step in the preparation phase is to place the necessary markings on the pieces of clothing that are cut. These markings may include pocket locations, pleats, etc. Prepared marking templates according to sizes and marking pens and soaps can be used for placing these marks. Sometimes the necessary markings can be placed on pieces of clothing with punching tools and threading tools.
After getting the necessary markings on the pieces of clothing, the pairing of the pieces begins. During this stage, pieces of clothing are mapped according to the size numbers and piece numbers of the models. Another preliminary preparation made before sewing is the process of fixing. During this stage, the necessary clothing is fastened with suitable presses and irons. Also, if embroidery is used as a decoration or a brand, embroidery processes are usually performed during the sewing preparation stage.
Sewing
In ready-made clothing production, sewing is the most important stage of production. During this stage, pieces of clothing are prepared to be sewed are combined through different sewing methods and different machines to form clothing. In ready-made clothing production, which is labor-intensive according to other industries, sewing needs a workforce more than any other section. According to the specifications of the clothing to be produced, the machines which are required according to the process to be done, the parts coming from the sewing preparation from the production lines are passed and the clothing is completed at the end of the belt. Poorly organized sewing processes are a waste of time resulting in poor quality and high cost. For this reason, businesses need to plan the sewing phase very well supporting it with well-selected machines and methods.
As in other industries, there are endeavors towards ready-made clothing production being completely automated. However, due to the effect of the varying fashion and the fact that businesses have to be flexible, it is not possible to be completely automated due to the property of the material used in production. In recent years, sewing machines have been programmed with the use of computer technology which minimize hand movements. Workers who work in such systems only feed the machine what has been already cut. Later, processes such as bringing the piece of clothing under the needle, giving the necessary forms to the piece, sewing, cutting the necessary places and stacking the finished work are done automatically.
As in other industries, there are endeavors towards ready-made clothing production being completely automated. However, due to the effect of the varying fashion and the fact that businesses have to be flexible, it is not possible to be completely automated due to the property of the material used in production. In recent years, sewing machines have been programmed with the use of computer technology which minimize hand movements. Workers who work in such systems only feed the machine what has been already cut. Later, processes such as bringing the piece of clothing under the needle, giving the necessary forms to the piece, sewing, cutting the necessary places and stacking the finished work are done automatically.
Quality Control
Quality control is another most important stage of production. People who work as quality controller check every details of the garment to sent them ironing.
All products with production problems are separated.
All products with production problems are separated.
Ironing
In ready-made clothing production, knitted or woven fabrics are affected by pressure, heat, humidity and vacuum parameters during ironing. The use of pressure during ironing can ensure creases, folds, smoothening of the upper surface and forming. During ironing, heat and humidity will affect the fabric that is ironed, and the desired effect can be provided through pressure. The vacuum-formed fabric is dried and the form or effect provided by the dryer can solidify the desired form or effect through cooling. By using these four factors in the right order, time and consistence, the desired ironing outcome can be obtained.
Ironing is very important in clothing production. Although ironing and forming are seen as one of the final processes, it is used throughout the production process to give a good appearance to the clothing and to facilitate the sewing process. The ironing processes used during the sewing process are interlining, stitching, pleating or folding, and simple forms. At the end of sewing, flattening and form ironings, which are evaluated between the finishing operations, are applied. According to the type of clothing produced, specially prepared ironing boards, interlining and form presses are widely used in clothing production.
Ironing is very important in clothing production. Although ironing and forming are seen as one of the final processes, it is used throughout the production process to give a good appearance to the clothing and to facilitate the sewing process. The ironing processes used during the sewing process are interlining, stitching, pleating or folding, and simple forms. At the end of sewing, flattening and form ironings, which are evaluated between the finishing operations, are applied. According to the type of clothing produced, specially prepared ironing boards, interlining and form presses are widely used in clothing production.
Packaging
After all the work on the clothing has been completed, the clothing is packed. The method of packaging applied in ready-made clothing production varies according to the type of product. Jackets, trousers, coats, etc. are packed on clothes hangers as they must be kept on hangers due to their characteristics. However, products such as sportswear, underwear and men's shirts made mostly of knitted fabrics are folded and packed according to their instructions. The purpose of the packaging process is to specify the size, color, color, etc. of the clothing, to prevent the wear and tear of the clothing during transport, to help them look smooth and clear, and to ensure that it reaches the customer reaches in a way that they desire. Another important point to note during packaging is the materials to be used in packaging. It is recommended to select materials from recyclable materials that do not create environmental pollution and those that are appropriate for the target consumer.
Shipping
All the products are assorted as requested by the customer then shipped with shipping company.