Professional Documents
Culture Documents
Make basic pattern: Basic pattern is made manually by pattern master in one base
size.
Digitizing: This base size is then digitized on the Gerber digitizer board.
Grading: After digitizing, its transferred to the computer on Gerber pattern design studio.
Patterns initially are made in only one size. We need to proportionally increase or decrease the
size of a pattern, while maintaining shape, fit, balance and scale of style details. Getting correct
fit and drape of a garment but also maintain the measurements as graded specs is essential.
Using the CAD system, the pattern is resized according to a predetermined table of sizing
increments (or "grade rules"). The computerized plotter can then print out the pattern in each
size.
Shrinkage adjustments should not distort the original shape and balance of the patterns. When
shrinkage is applied to a panel in garment all corresponding patterns must also be applied with
shrinkage adjustments.
Gerber plotter printing: The patterns are then printed on the Gerber plotter. They
are then pasted to thick aortic sheets and converted into full fledged patterns.
OTHER CONSIDERATIONS
Efficiency: Marker plans indicate efficiency of the cutting process i.e. the efficiency of
fabric consumption.
Lay plan: determines the no. of lays required to cut the specified quantity in the
predetermined size ratio.
Precision in checks in stripes
When the fabric is in-house, it should be capable of being supplied to the cutting department.
Inspection is done prior the cutting room issue so as to remove the defective fabrics.
Fabric issued to cutting room as and when required. SOFT ( NIFT, Pune )
FABRIC VISUAL INSPECTION
The 4 point system is generally used for fabric inspection. In this system, points
are assigned for every possible defect in the fabric as follows.
Major woven defects : slubs, holes, missing yarns, yarn variation, end out,
soiled yarns, wrong warns.
Major dyeing or printing defects: out of register, dye stops, machine stops,
color out, color smear, or shading.
These defects are marked wth colored tape so that they can be easily
located.
3. There should not be a major defect within 5 meters from beginning or the end of the roll or
part therein.
5. There should not be shade variation from selvedge to selvedge, centre to selvedge and start
and end
6. A repeating defect or running should not extend for more than 3 yards (2.73 meters),
otherwise the roll will be considered second quality.
FABRIC TESTS
o Fabric Shrinkage is a very important factor for any physical inspection. Mistakes in
appropriate checking might prove disadvantageous for the pilot run followed by
production. An optimum conduction of the width and shrinkage properties has to be
made. The fusing of lining to some parts may also be done in the cloth store. If the shrink
characteristics are consistent, then the patterns may be designed to the correct oversize
and sampling checks for consistent shrinkage carried out. Color changes can also occur at
the time of fusing as the temperatures might have been controlled or were out of the
prescribed limits.
Or
50 * 50
According to the above picture, a fabric piece of the above mentioned specification is cut
and marked accordingly. Then a wash with a soft enzyme is given. The deviation is
shrinkage if any is marked between the points. Shrinkage of 1-1.5 cm is acceptable. If it is
more than this then the merchandiser is supposed to take the desired action.
o C.S or Centre Selvedge test: This test is used to check the color variation in the fabric.
Full width of the fabric is taken (length can vary according to requirement say 10). The
Fabric is divided into 6 pieces and their grain line is marked.
These pieces are then cut and re stitched in a random series. For e.g. 3, 6, 2, 5, 4, 1.
When we arrange these fabric pieces in a series, we can see the shade variation in the same
fabric. Noting of this variation is very important at the time of cutting.
o Others include dry clean and washability, abrasion resistance, pilling (especially for mixed
fibers), Bow and skew (using a ruler and set square for checks and stripes), Drape and crease
resistance (that includes permanent press capability), Strength (tensile, tear and bursting (for
seams), Flammability, Surface wetting and penetration.
FABRIC DEFECTS
o Abrasion Mark: A place in the fabric where the surface has been damaged
due to friction or abnormally weakened by any operation through which it
has been passed.
o Misprint: In printed fabrics, either missed, or partially missed, or incorrectly
positioned relative to each other.
o Double Pick: Two yarns running simultaneously, mostly in the weft yarn.
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o Oil Stain: Oil mark on the fabric.
o Hole: A breakage of yarns in the fabric involving more than two yarns.
o Bow: When the weft/filling yarns lie in an arc across the width of the fabric.
o Skew: Distortion in the construction of the fabric i.e. in the yarn that
constitute the fabric.
o Crease: A fabric defect across the fabric width usually caused by a sharp
fold.
o Dye Stain: An area of discoloration due to uneven absorption of colorant.
o Miss-pick: A pick/weft yarn not properly interlaced.
o Slubs: An abruptly thickened place in a yarn.
o Screen Out: The appearance of a colored separation line in a printed
design.
o Calendar Line: Sharp pressmark on fabric due to the calendar during the
processing.
o Contamination: Colored fibers with the warp or weft fibers.
Name of suppliers
V.C.M synthetics, Symbolic fabrics, Arvind mills, Ashok weaving, Vaibhav trading,
Siyarams, J Hampstead.
Trims card to be readily available for each of the PO/style being processed that is duly approved
by the nominated quality assurance person.
As soon as the work order is received, a fabric enquiry is conducted in fabric store weather the
fabric is available or not. The CAD department is responsible for making the pattern markers
available in various graded sizes for cutting purpose and calculate the consumption per
garment.
SPREADING
- Spreading is the process of unwinding large rolls of fabric onto long, wide tables and
laying them in superimposed plies of specified length.
- The number of lays depends upon the number of garments desired and the fabric
thickness.
- The maximum cutting width is the usable fabric width minus selvedge or needle marks
caused by stencil marks.
- Fabric utilization is the amount of fabric actually utilized in the marker as the percentage
of the total fabric area.
Type of lay: Multiple Ply is used in which a number of fabric layers are stacked on one
top of other.
Forms of spreading: Fabric is laid the same way up with grain or print pattern running in
the same direction. Fabric has to be cut at the end of each ply.
Laying parameters
Pattern matching.
Relaxing the fabric to remove all the tensions.
Allignment of ply edges in correct position over each other.
Lay order plan :
Example 1
39 40 42 44 Total
31 40 40 20 131
48 62 62 31 203
37 48 48 24 157
43 58 58 29 188
679
Average no of lays
131
CUTTING
Cutting parameters:
- Precision in cutting: To ensure the cutting of fabric - accurately according to the line
drown of the marker plan.
- Clean edge: By avoiding the fraying out of yarn from the fabric edge. Cutting edge must
be smooth clean. Knife must be sharp for smooth or clean edge.
- Consistency in cutting: All the sizing safe of the cutting parts should be same of knife
should be operated of the right angle of the fabric lay.
EMBROIDERY DEPARTMENT
Embroidery pattern is received that specifies the no. of stitches, colors, the pattern, size and
placement.
Embroidery machines:
Types of motifs: Institutional logos (jindal, essar, cyberoam), kids wear motifs (cartoons),
company logos (oxerberg, J hampstead), jeans back pocket embroidery, shirt cuff and front
panel embroidery are done.
SAMPLING DEPARTMENT
The sampling for each season begins according to the product cycle of style. This process is also
called Product development (P.D). One should also know the tentative size ratio in each style.
This is because the costing of the product depends highly on the fabric consumption. Kinds of
samples prepared:
PRODUCTION DEPARTMENT
Sewing Process
Industrial Sewing
Industrial sewing is quite a complex process involving many preparations and mathematical
calculations for the perfect seam quality. Good quality sewing also depends on the sound
technical knowledge that goes into pattern designing and making. Flat sheets of fabric having
holes and slits into it can curve and fold in three-dimensional shapes in very complex ways
that require a high level of skill and experience to manipulate into a smooth, wrinkle-free
design. Aligning the patterns printed or woven into the fabric also complicates the design
process. Once a clothing designer, with the help of his technical knowledge, makes the initial
specifications and markers, the fabric is then cut using templates and sewn.
These undesirable variations in the cloth tension affect the product quality. Therefore, there
arises the need of strict control over the whole process. The work of sewing is focused on the
handling of fabrics lying on the working table and guide them towards the sewing machines
needle along the seam line. The attention is equally focused on the control of appropriate
tensional force so as to maintain high quality seam.
When the fabric is placed on the working table, the tasks that are performed before the
sewing process include - recognizing the fabric's shape, edges that will be sewn, planning of
the sewing process and identification of the seam line.
Sewing Fabrics
The sewing process consists of mainly three functions - guiding fabric towards needle; sewing
of the fabric edge; and rotation around the needle. The fabric is guided along the sewing line
with a certain speed that is in harmony with the speed of sewing machine
The orientation error is either manually monitored or if monitored automatically then error is
fed to the machine controller so that the machine corrects the orientation of the fabrics.
When one edge of seam line is sewed, the fabric is rotated around the needle till the next
edge of the seam line coincides with the sewing line. The sewing process is thus repeated until
all the edges of seam line planned for sewing, are sewed.
Thread tension and consumption: Correct balancing of the stitch and the tension given to the
threads is very important for quality stitch formation. Thread consumption, which is closely
associated with correct stitch geometry and thread tension, is usually measured by digital
encoders.
Presser- foot displacement and compressing force: Presser- foot is the part of the sewing
machine that holds the fabric in place as it is being sewn and fed through by the feeder. The
feeding system is one of the most important constituting systems of the sewing machine. If
this system is not efficient then it results into irregular seams and many other defects,
especially when running on high speed. To evaluate feeding efficiency, the force on the
presser foot is measured with the help of electric or other sensors.
Needle penetration force measurement: The interaction of needle with fabric is very crucial.
Fault-free needle penetration depends chiefly on the properties of fabric and needle choice.
Needle penetration force is one of the variables whose measurement is important for the
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analysis of quality problems or "sewability testing" and also quality monitoring. It takes
various factors into consideration, such as the needle geometry (including the point angle and
point length of the needle), the friction between the needle and the fabric, the friction
between the needle eye and the thread along with fabrics' property, and the sewing
conditions.
During the course of garment production, i.e right from cutting to final dispatch, Oxemberg
QAD team will conduct various inspections as follows:
1. Inline/mid inspection : This will be carried out during the production of garment in
order to carry out this inspection effectively following information is a must.
A) Updated W/O sheet
B) Style approved, saple approved by the merchandiser
C) Fabric, trims and accessories cards rectified by the merchandiser.
D) Approved measurement specification.
ii. Scheduling: The work is allocated to the production capacity according to the agreed
plan as soon as the orders are confirmed. It is at this stage that schedules are prepared
as an exercise and later drafted in detail.
iii. Controlling: The production process is very uncertain and rarely goes according to the
schedule, especially when the processes are complex and dependent on the
performance of individuals. Sometimes orders are cancelled and rush orders come
through. Inefficiency can be avoided if the preliminary work is done thoroughly and the
routine terms are accurately recorded. Balancing is a part of the process.
i.Time/ unit input: e.g. meters of cloth or SAM of work per minute.
iii.Technical maintenance: Proper usage and maintenance of the machines and other
electronically equipments should be done to provide smooth operation processes.
v.Non productive hours: A provision for non-productive hours should be provided in the total
available minutes as these by default are bound to happen. For e.g. lunch time, talking, going to
washroom, sitting idle etc. These hours can be deceased by making changes in the production
plan wisely.
vi.Line balancing: This is necessary to reduce the wastage of time as some workers might be
sitting idle because the feeding has not been done properly and the pieces are not being
delivered to them on time. The overall operation machine layout is faulty due to improper line
balancing. A machine layout is considered to be optimum if all the machines in the line are
producing their required quantities of pieces and no worker is sitting idle. Line balancing can be
a way to increase the productivity as increasing or decreasing unwanted operations from the
line can be done.
vii.Analyzing labour requirements and deficiencies: A difference in skilled and non-skilled labour
can be assessed and accordingly work can be assigned to them.
viii.Optimum utilization of time and raw materials: Any type of unnecessary wastages should be
avoided as far as possible. This requires a good production plan and the co ordination of related
activities.
Production flow
This refers to the series in which the garment moves from one workstation to another,
requiring completion of the desired operation. The garments move from one work station to
another in a straight line. The straight could be work stations set up on either side of a belt
conveyer/runner table. There is little amount or work in process between the stations. In these
Quality implies value. It is something that is build into the garment from the stage of market
research and design right up to pack and dispatch and extends beyond a careful analysis of the
customer returns and consultation with the buyers. The quality of the garment is the reason
that is bought by the customer and comprises of a set of quality characteristics which together
make up its fitness for purpose. The key to profitable garment manufacture is to provide the
best combination at lowest cost the economic quality level.
The main function of the quality control department is not to control quality but to provide a
service which allows people to make good clothes. Their main concern should be to do this at the
minimum cost, balancing the expense of the department against the savings in terms of reduced
repairs and rejects. One aspect of this is to define the quality level of plant and of the workplace
in it. The raising of quality levels requires a major project involving investment in machinery and
training which cannot be done quickly.
The maintenance of quality at an agreed level implies clear specifications and these are an
important task for this department. The Product information sheet for individual styles can be
kept as brief as possible. They should contain the maximum information in the form of sketches
and all dimensions should me quoted with tolerances. Tolerances reflect the extent to which less
than perfect is acceptable. However, small tolerances exist for the garments.
The function of the quality control department is to reduce the amount of bad work being made.
This gives savings in cost of the repairs and rejects but also speeds up delivery. Its aim is to make
garments correctly at the first time. When the consistency of quality is poor, the expected quality
level is substantially below standard. Greater consistency has an even higher priority than raising
the standard of the majority of the garments made.
Tolerances
These are the limits of acceptability expressed in figures usually or by examples or photographs
to demonstrate the limits of acceptability. For example, the specification for a seam margin may
be 1 cm and the tolerance is -/+2 mm.
Quality Specifications
o Factory specifications
Cloth and trimmings, button spacing
Threads, needle types and sizes, by fabric and seam type
Stitches per inch or per 2 cms
Seam types, seam margins and tolerances
Cutting standards
1) FABRIC STORES:
o Neatly arrange the fabric rolls received and maintaining the department cleanliness to
avoid spotting and contamination of the fabrics. Packing the fabrics in plastic sheets can
be useful.
o Fabric inspection is done on 4 point system.
o Shade cards/fabric quality swatches for each style approved by the PO are maintained.
2) TRIMS STORES:
o Trims stores have racking system to store the trims in a proper order.
o Trims card for each PO/style being processed should be maintained.
3) CUTTING SECTION:
o Making CSV ( centre to selvedge variation) sample for each of the roll to analyze
the shade variation.
o Maintaining shade samples and providing shade details to presentation checkers
in finishing dept for shade reference.
o Proper pattern checking report.
o Proper lay check, marking check, sorting/bundling check report.
o Cutting projection tallies updated.
4) SEWING SECTION
o Effective maintenance for each of the machine.
o Proper updated broken needle log (should have needle issuing record from
stores and properly pasted broken needle book).
o Keyhole, bartack, overlock, label attach operation internal approvals and display
of mockups.
o Effective mockup system on all operational areas.
o All scissors and trimmers should be secured properly.
o Clearance of WIP at all levels.
o Display of trim card at required areas.
o Checking garments before wash and after wash for both quality and
measurement.
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o Random in-line checking at each chain stitch operation like feed of arm machine.
o Each supervisor is advised to check randomly the operation in their own working
limits.
o Each operator is advised to clean their machine and area before start of work in
the morning and after lunch- waste fabric is issued to the operator for the same.
o In-line and end-line checking report.
o Before wet processing in-line audit report is also maintained.
o Washing facility is not available in-house. Its done on jobber basis.
5) FINISHING SECTION
o Fabric defect identification by stickering and alteration piece identified by
knotting at place of alter by the checker.
o Dusting is done by dust pads wherever sucking machine is not used.
o Cartoons are properly stacked.
o Presentation checker to have ready reference of shade cards of fabric and trims
cards as well.
o Daily checking report is maintained.
o Measurement audit report is maintained.
o Pre-final auditing is also gone on garments.
o Defective cartoons are replaced by good cartoons.
1. Fabric Store: In the fabric store fabric is being checked before issuing it to cutting
department. In general not all the fabric is checked. 100 % fabric checking is done. Fabrics are
checked in flat table, flat table with light box or on fabric checking machine. 4 point system for
fabric inspection is used to measure the quality level of the incoming fabric.
2. Trims & Accessory: Trims quality is also very important for having a quality garment.
Trims inspection is done randomly against the given standards, like color matching. But for
trims and accessories quantity checking is essential.
3. Cutting Room: It is said that cutting is the heart of production. If cutting is done well
then chances of occurring defects in the following processes comes down. In cutting room,
check points are I) marker checking, ii) cut part audit and iii) bundle checking.
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4. Embroidery checking: It is also not a compulsory process. If there is embroidery work in
the garment panels then 100% inspection is done before issuing to sewing.
5. Sewing Department: Checkpoints in the sewing departments are as following.
- Inline inspection: In assembly line generally check pints are kept for the critical operations. In
these checkpoints, 100% checking is done for partially stitched garments and defect free pieces
are forwarded to the next process.
- Roaming inspection: In this case checkers roam around the line and randomly check pieces at
each operation.
- End of line inspection or table checking: A checker checks completely stitched garment at the
end of the line. 100% checking is done here.
- Audit of the checked pieces: 100% inspected garment are sent to finishing from sewing
department. And all defective pieces are repaired before sending to finishing.
6. Finishing Department: Check points in finishing department consists
- Initial finishing inspection: checking done prior to pressing of the garment at finishing room is
known as initial finishing.
- Final finishing Inspection: After pressing garments are again checked and passed for tagging
and packing.
- Internal final audit: After garments are packed up to certain quantity, quality control team,
does audit of packed garments. This process is carried out to ensure that before handing over
shipment.
If the completed work is being checked at each process and defective pieces are corrected
before handing to the next process than at the end of production there is very little chance to
have a defective at final inspection stage.
Washing: Sometimes, the buyers demand that garments must be given a wash after
stitching.
Extra Thread trimming: The extra threads which have been left uncut are trimmed. This can
be done manually with thread cutters.
Stain removal: Different types of stains might be formed at the time of garment handling
operations. Different kinds of stains include ball point stains, oil stains, dirt stains etc. Different
kinds of chemicals are used for their removal. For example, Ball point stain is removed with ink
remover, stains on white fabrics are removed with a chemical called Ariel lines, Ltk-45 is used
for removing yellow and black stains from colored fabrics, N-9 is used to remove stains on light
colored fabrics, Emrol-ol and petrol is used to remove other hard stains.
Thread sucking : this is done to remove the threads stuck to the fabric surface that are too
minute to remove. For this, a thread sucking machine is used to remove threads with air blow
and vaccum sucking. Also, adhesive tapes are wrapped on rolls and then moved over the
garments, especially in trouser finishing this step is essential.
Alteration: Any garment found faulty of defects will be sent for alteration.
Ironing: After all these steps, the garments are ironed in a proper manner, folding on the
right creases. Steam ironing is preferred. The garment measurements are continuously
monitored at the time of ironing also. The garments can be shrunk or stretched to some extent
in case the measurements go beyond the tolerance levels. Ironing depends upon the type of
fabric viz. knitted or woven. Knitted garments require light pressing where as wovens require
deliberate wrinkle removal and crease setting. A dolly or body form press is also used to trouser
pressing.
WORKFLOW OF FINISHING
TYPES OF DEFECTS
Color defects that could occur are difference of the color of final produced garment to the
sample shown, accessories used are of wrong color combination and mismatching of dye
amongst the pieces.
Broken buttons
Broken snaps
Broken stitching
Creasing of garments
Defective snaps
Different shades within the same garment
Dropped stitches
Exposed notches
Exposed raw edges
Fabric defects
Holes
Inoperative zipper
Loose / hanging sewing threads and buttons
Misaligned buttons and holes
Missing buttons
Missing stitches
A rotation, usually lateral, between different panels of a garment resulting from the release of
latent stresses during laundering of the woven or knitted fabric forming the garment. Twist may
also be referred to as Torque or Spiraled.
Instead of rejecting the defective garment, only damaged part can be changed and converted it
into a quality garment. It should not increase the fabric consumption or produce further
defective garment in the part changing process
WASHES
a. Softener wash ( enzyme wash )
Its of 3 types ionic, non-ionic, and cationic.
b. Enzyme wash
OT, desizer, lubricant, water washing at 52degrees, Acetic acid (pH), Enzyme (to
stabilize), Water wash, Silicon, softener.
c. Detergent wash
Ariel and tide
d. Leather wash
e. Powder wash pumice in powder form
f. Pumice stone wash
PRECAUTIONS
FABRIC X
Pigment padded fabric No heavy wash is given Enzyme wash, leather
because it can cause color wash can be given.
bleeding.
White garment No heavy wash Enzyme wash.
Worsted fabric No heavy wash Beach ball wash,
chlorine bleach (
caco2 + thermal balls)
Trouser Heavy wash
Shirt fabric
Yarn dyed
DENIM WASHES
o MACHINERY USED Front vertical loader m/c: (98kg, 150kg, 300 kg).
1. Tucking : The piece is tucked with the help of tucking machine at the
place where we want to have the wash effect.
2. Scraping: Sandpaper is used to scrap the fabric to reveal the faded
effect.
3. Spraying: Dyes are sprayed over the garment in different angles and
strokes to reveal the sprayed effect.
4. Whiskering:
5. Crinkling
6. Crackle: The piece is tied at the place where we want to avoid color
penetration in pleats and then dyed.
of waistband stitching, seat seam on top of riser seam) resulting in stitch failure.
- Use a larger diameter thread on operations where the thread is being cut.
- Make sure the proper stitch balance is being used. On a chain stitch seam on
- Change the needles at regular intervals on operations where the Needle Cuts
etc. Broken stitches must be repaired by re stitching over the top of the stitch-line.
degradation.
- Using larger thread sizes when the Denim Garments will be subject to Harsh Chemical
washes.
- Making sure that the water temperatures and PH Levels are correct and that the
- Make sure the garments are being rinsed properly to neutralize the chemicals in the
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fabric.
- Monitor the drying process, cycle times, and temperatures to make sure they are
4. Unraveling Seams:
Generally occurs on 401 chain stitch seams where either the stitch has been broken or a
skipped stitch has occurred. This will cause seam failure unless the seam is Re stitched.
2. Cut or broken stitches during a subsequent treatment of the finished product (I.e.,
stone washing).
- Make sure sewing machines are properly maintained and adjusted for the fabric and
sewing operation
6. Skipped Stitches:
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Where the stitch forming device misses the needle loop or the needle misses the looper loop.
Skips are usually found where one seam crosses another seam and most of the time occurs
- Use the ideal foot, feed and plate that help to minimize flagging.
0- Instruct sewing operators to use proper handling techniques and not stretch the fabric
- Where, available, use differential feed to compensate for the stretch of the fabric.
8. Ropy Hem:
- Where hem is not laying flat and is
skewed in appearance.
9. Twisted Legs:
Is where the side seam twists around to the front of the pant and distorts the appearance of
the jeans.
It is the thread picks up the indigo dyes from the fabric giving the thread a 'dirty' appearance. A
common discoloration would be the pick-up of a greenish or turquoise tint.
- Correct PH level (too low) and Water Temperature (too low) during laundry.
altogether.
- Use threads from the same thread supplier and do not mix threads in a garment.
- Make sure sewing operators select thread by type and color number and do not
just pick a thread off the shelf because it looks close in color.
Order Processing
Inventory Check
Replenishment of stock
Intimation to customers
Dispatch of goods
Collection of payments
Packaging
Packing is traditionally meant to protect goods. However, it is also a promotional tool and a major image
builder contributing to product success. Packing is a process that speaks of companys ability to contain
economically man made or natural products for shipment, storage, sale or final use. Packaging on the
other hand deals with activities of planning and designing of different means of packaging the product.
However, it should be noted that packing is concerned with product protection while packaging is
concerned product promotion.
Objectives of packing
Protection of the product: To keep the garments clean, fresh and unspoilt by using moisture
proof and damage resistant materials. Its done basically to avoid any type of deterioration or
contamination of the garment. The main aim is to maintain the quality of the garments intact
unaffected by dust and dirt.
Product identification: Packing is a convenient way to identify the products of different buyers as
each buyer would have a different type of packing requirement. The size, color combinations,
graphics used in each package are unique and can be easily remembered.
Product convenience: Packing aims at providing maximum convenience to the purchasers,
producers and distributors alike. A nicely designed product package facilitates product shipping,
storage, stocking, handling and display on part of producers and distributors. Neat packing can
bring reduction in inventory costs, packing cost, space and time costs.
Product package promotion: A good packaging performs effective advertising function. The
general appearance and selling features created by the packaging techniques decide the product
success. As a promotional tool, it does self advertising, displaying, publishing and acts as an
advertising medium.
It should protect the contents: A good packaging is a means of preservation of products from
possible damage or loss in value. The quality of the garments is maintained intact. The packing is
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designed to protect it against natural and artificial factors of damage like dirt, dust, theft,
shrinkage, contamination etc.
It Should be attractive: Apart from protection, seeking the attention of the consumers is also
essential. Package design, weight, material, color combinations, graphics, texture, illustrations
etc form the essentials of a good package. Some customers buy products because they are
impressed by the packing. Therefore, package attraction generates impulsive buying.
It Should provide convenience: Good packaging increases product sanitation, ease in handling,
transportation, storing and using packages. The package so designed should grant highest
degree of convenience to manufacturers, distributors and consumers alike. Consumers are
seeking packages that are easy to handle, open and reusable.
It Should be economical: Economy is something that reduces not only packing and its expenses,
but also brings down other allied expenses such as transport, warehousing, tax-levies and
handling. Cost reduction are possible through multi-packaging allows more cost re3duction than
when one pack is sold on its own.
It should be pollution free: It is a well known fact all over the world that packing has
environmental problem, particularly the discarded packing. Hence it is advisable to use recycled
or bio-degradable packaging materials that minimize pollution.
It should be informative: Provision of information about product illustration,
features/specifications, instruction to handle, prices, the amount of product in the package, the
content brands name, and other relevant information for the consumer as well as distributor.
Detailed labeling is a must.
It should assure adjustability: The packaging should have the ability to adjust or flexibility to be
put to different uses. Paper packaging is known for cheapness and lightness.
It should be labeled: Labeling is the act of attaching or tagging labels. A label may be a piece of
paper , printed statement which is either a part of a package or attached to it, indicating value
of contents, price, product name, and place and name of producer. Thus, a label is an
informative tag, wrapper or seal attached to a product or products package.
In designing a new product package or redesigning the existing one, the manufacturers take into
account:
Nature of product: The type of container to be used depends upon the form and ingredients of
the product. Transparent containers are most suited for attractive colors and appearance,
vacuum sealed ingredients for volatile ingredients and glass containers to minimize chemical
reactions. Plastic and metal packages can also be used.
Costs: The cost of packing must be absorbed by the production economies, increased sales
volumes or higher price. The packing material, label, filling and closure costs, handling,
distribution and breakage cost of package are important.
Family resemblance: If the product is one of a number of related items, its advisable to design
the package that confirms to the containers of other products in the same line to assist
consumer and dealer identification
Advertising value: Unique shape, attractive design gives a package greater sales and advertising
value.
Legal requirements: the packages must confirm to the laws prohibiting the deception of
consumers by the use of false bottoms, slack fill and other means of giving an impression that a
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package contains a larger quantity than the case. There are legal requirements prescribing the
copy appearing on the labels of the cartoons which should be confirmed to.
Test the design in the market: test-marketing must be conducted in the market to get indirect
replies through dealer feedback.
Environmental checking: the packing development decision may be influenced by legal,
ecological and social forces. Thus issues like consumer packing safety, disposable packing, the
quantity of packaging, littering, wise labeling and so on.
Packing strategies
After the garments arrive from the finishing and quality check department, they are packed in hangers or
simple fold pack in polybags, according to buyer requirements. Here, multiple packaging strategies are
followed. It is a kind of strategy in which a no. of closely related but heterogeneous products used by one
consumer are placed in a single package. Such a package conveys that idea of an ideal matching set that one
should possess. For example as in case of assorted collection kids wear packages are packed along together.
It facilitates acceptance of a new product idea by a consumer who normally may not want to venture into
buying it. However there is danger of the whole package being rejected through a consumer who is
interested in only one or two items in the total set. Since the consumer will have to buy the whole set he will
reject the 2 items he was favoring a will not buy the set.
Inventory
Inventory management is a task of planning and controlling of finished goods after they have been bought
from the production department and before their delivery to the users. It has 2 parts: Inventory and
Warehousing.
Warehousing: This performs two functions namely movement and storage of goods. Movement
refers to the actual receipt of products from the manufacturing centre their transfer in the
warehouse and stocking at designated place, assorting to consumer orders and transferring them to
common carriers on their way to consumers. The storage function is mainly concerned with holding
and caring the goods from the time they are placed in, till they are places out in common carriers. It
is basically a safety and preservative function.
Inventory controlling: Inventory implies the stock of goods held over a period of time for meeting
the consumer needs. For the production department, inventory means stock of raw material,
machine and parts, stock of goods partly manufactured and finished goods. For the distributors or
dispatchers, it is the finished stock meant of the final consumption.
Material Handling
This refers to the handling of the goods ready for dispatch. They can be classified into:
Manual: This involves usage of human labour. This is restricted to areas with unorganized plant
layout and costs of movements.
Mechanical: This involves the use of machines driven by power like for e. g cranes, trucks,
stackers, side loaders, mobile cranes etc. these have more fixed costs if the capacity utilization is
less.
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Automatic: These are fully automatic operated by automatic machines and computers. These
require heavy capital investments.
For example :
Brand Qty
Oxemberg 60 ics
Beach pebble 48 pcs
MSD Inner packs pakaging
J Hampstead 3 boxes
33pcs 48pcs 60pcs
The packing quantity per carton depends upon buyer specifications.
o Packing stratergies:-
1. MSD ( casual )
1 small inner 12 shirts.
So 1 big inner=5 inners = 60 shirts
Jeans pack size ratio wise
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2. TROUSER ( oxemberg )
1 inner = 16-17 pieces
3.
o Storage: Racking is done size wise, style wise, garment wise, sleeve length wise(half
sleeves/full sleeves). Each rack is given a rack no. Restickering according to buyer
mentioned in memo.
o Storage capacity: Shirt: 80000-2,00,000 & Trousers and jeans 30,000 pcs
o Distributor (MSD & Oxemberg)