MASTER OF FASHION MANAGEMENT

FASHION PRODUCTION AND QUALITY

MANAGMENT
MID-TERM ASSIGNMENT

— Bharti, Ekagra, Shivangi, Tarun, Vanshika, Varun

Introduction to pre-
production process

The pre-production process in the apparel industry

is a critical phase where design ideas are
transformed into feasible garments before
manufacturing begins. It involves collaboration
between teams and key steps such as design
development, material sourcing, and quality
control. Efficient pre-production planning is
essential for mitigating risks, optimizing resources,
and meeting consumer expectations. Additionally, it
fosters innovation, sustainability, and ethical
practices, positioning businesses for success in the
competitive global market.
 Importance of pre-production process

Cost Efficiency: Quality Assurance: Time Optimization:

Efficient resource allocation and cost
management.
Minimize wastage, reduce errors, and
optimize resources.
Uphold stringent quality standards
from the outset.
Meticulously design and prototype
garments.
Implement quality checks at every
stage.
Streamline production schedules and
minimize lead times.
Accurately estimate production
timelines and resolve bottlenecks.
Capitalize on market opportunities
and gain a competitive edge.
 Importance of pre-production process
Flexibility and Adaptability:
Adapt to changing market demands and
consumer preferences.
Conduct thorough market research and
maintain open communication.
Swiftly adjust production plans and
incorporate new technologies.
Risk Mitigation:
Identify and mitigate potential risks and
challenges.
Conduct comprehensive risk
assessments and address vulnerabilities.
Safeguard against disruptions and
maintain business continuity.
Sustainability and Ethical
Considerations:
Promote sustainability and ethical
practices.
Prioritize environmentally friendly
materials and waste reduction.
Adhere to fair labor practices and meet
consumer demand for ethically
produced garments.
Steps in pre-
production
process
Meeting with Buyers and Initial Sample
Development
Meeting with Buyers: Development of Initial Samples for the Buyer:
• Purpose: • Proto Sample Development:
• Showcase manufacturing house's creations and latest • First sample developed from design sketch or concept.
designs to potential buyers.
• Made in matching fabric quality (weight and type).
• Discuss any fixed designs requiring modifications
• Typically, in one size due to unavailability of actual
related to fit, fabrics, or trims.
fabric.
• Participants: • Usually, three samples made:
• Designers from the manufacturing house present their • 2 sent to buyer for approval; one kept by buyer,
creations. one returned to factory.
• Merchandisers liaise with buyers regarding fixed • 1 for factory's counter sample of proto.
designs and necessary adjustments.
• Additional sample may be required if involving a
• Discussion Points: third-party buying house.
• Presentation of new designs and collections.
• Clarification of buyer's requirements and preferences.
• Negotiation on design modifications, fit adjustments,
fabric choices, and trim preferences.
 • Direct Costs: • Indirect Costs:
Costing of 1. Materials: 1. Factory Overheads:

garments 1. Fabrics, trims, accessories.

2. Quantity, quality, unit cost.
1. Rent, utilities, maintenance.
2. Depreciation, insurance,
admin expenses.
2. Labour:
2. Quality Control:
1. Wages, salaries, benefits.
1. Inspection, testing, rework.
2. Overhead expenses.
3. Sampling and Prototyping:
3. Trimming and Embellishments: 1. Material, labor, overheads
1. Additional decorations or for prototypes.
treatments.
4. Transportation and Logistics:
4. Packaging: 1. Transporting raw materials.
1. Packaging materials, labels, 2. Shipping finished goods,
tags. freight charges.
 • Miscellaneous Costs: • Profit Margin:
Costing of 1. Duties and Taxes: • Added to cover overheads,
garments 1. Import duties, customs
duties, taxes.
returns, growth objectives.
• Calculated as a percentage
2. Bank Charges and Finance of total production cost.
Costs:
1. Fees, charges, interest
expenses.
3. Contingency:
1. Provision for
unforeseen expenses.
 Pattern making, correction of pattern, pattern grading

Building on the The Pattern Fit is King Testing, Time Bridging the
Prototype Master's Role Testing... Management is Gap
Key
Proto sample Factory experts create Garment fit is crucial Fit sample is assessed 45-day target for fit One-month buffer
approved! the initial fit pattern. for sample on a live model or sample submission between proto
Fit sample uses actual Adjustments are development success. dress form. (after proto approval). approval and fit
measurements for a made based on 2-3 samples are Bulk fabric needs sample submission.
more precise fit. desired fit. created to ensure time for delivery (20-
optimal fit. 25 days).
Buyer may nominate
fabric supplier or
provide it directly.
Development of fabric sample
1. Fabric Selection:
1. Criteria include color, fiber content, texture, hand feel, and physical/chemical
properties.
2. Factory explores market or collaborates with suppliers for required fabric.
2. Fabric Development:
1. Garment maker provides fabric quality requirements to suppliers.
2. Negotiation of fabric price and development of lab dip and desk loom.
3. Testing fabric samples to ensure desired quality before bulk order.
3. Bulk Fabric Approval:
1. Fabric swatch sent to buyer for approval.
2. Bulk fabric sourced from pre-approved suppliers based on consumption
calculations.
4. Fabric Quality Inspection:
1. Fabric checked for faults and defects using systems like the 4-Point System.
2. Tests include GSM, shrinkage, and color bleeding.
3. Pre-shrinking and pattern modifications may be necessary based on test results.
Development of fabric
sample
5. Fabric Sorting and Shade Banding:
• Fabrics processed in different lots leading to shade variations.
• Shade bands prepared to ensure consistency in garment color.
6. Sourcing for Trims and Accessories:
• Trims and accessories purchased in advance of production start.
• Consumption per garment calculated to determine requirements.
7. Quality Checking of Trims and Accessories:
1. Inspection and approval of trim quality before production.
2. Testing for color bleeding in trims like laces, tapes, buttons, zippers,
and draw cords.
3. Defective items separated to ensure only quality trims are used in
garments.
Fit Sample and Salesman Sample Development
Process

Fit Sample and Approvals and Salesman Sample Timely Submission:

Salesman Sample Corrections: Importance:
Making:
Samples crafted in the Samples sent to buyer for Displayed in showrooms for Buyer pays for salesman
sampling department approval. customer assessment. samples, emphasizing
according to design Buyer provides feedback for Customer feedback used to importance of timely
specifications. further work or corrections. forecast demand for specific submission.
Fit samples for assessing Corrections made and styles. Order size influenced by
garment fit and fall. resubmitted for buyer Made with actual fabric, trims, sample quality and timeliness.
Salesman samples displayed in approval. and accessories. Delays or quality issues can
retail showrooms for customer reduce order size.
feedback.
Size Set Sample and Garment Performance Test
(GPT)

Garment
Size Set Sample Size Set Sample GPT Approval
Performance Test Timely Execution:
Objective: Importance: Process:
(GPT):
• Evaluate garment fit • Crucial stage for • Mandatory for • Buyer doesn't ask for • GPT conducted
across multiple sizes ensuring correct fit clearing buyer's GPT sample simultaneously with
(e.g., S, L, XXL). before bulk requirements. submission; requires Size Set sample to
• Number of samples production. • GPT sample sent to test report. avoid delays.
determined by • Corrections made to third-party • Test results must be • Ensures timely
buyer's requirements. pattern grading if inspection or in- approved by buyer submission of PP
• Pattern grading needed. house testing lab. well in advance of sample and Planned
checked for • Actual fabric used; • Tests defined by PP (Pre-Production) Cut Date adherence.
accuracy. similar quality may buyer's protocol. meeting.
be used if actual
fabric unavailable.
Pre-Production Sample
Approval Process
1. PP Sample Preparation:
1. Made in actual production line or sampling department.
2. Crafted with actual fabric, trims, and accessories.
3. Typically, 3-4 PP samples made for one style.
2. Purpose of PP Sample:
1. Allows operators to understand what they will produce.
2. Ensures adherence to style specifications.
3. PP Sample Distribution:
1. Samples sent to buyer for cross-checking detailing and workmanship.
2. Typically, one sample for buyer, one for vendor, and others for internal use.
4. Buyer Evaluation:
1. Buyer reviews sample for compliance with style specifications.
2. Approves PP sample if everything is as per requirement.
3. Variations may prompt re-submission or comments for correction in bulk production.
Pre-Production Meeting and
its importance
Purpose:
• Align all stakeholders involved in garment production.
• Reduce chances of mistakes in bulk production.
• Clear any misconceptions about the product and address issues.

Benefits:
• Ensures everyone understands the production process.
• Facilitates building strong relationships between buyer agents
and factory personnel.
• Group discussion aids in improving production processes.
Methods of Pre-Production Meeting
Meeting Places:
Held in apparel factories or buying houses.
Processes similar but slight variations exist.
Personnel:
Apparel Factory: General Manager, Buying QC,
Factory Manager, Production Manager, Quality
Control Manager, Merchandiser, Maintenance
Mechanic, Pattern Master, Sample Maker,
Cutting Master, Sewing In-charge, Finishing In-
charge.
Buying House: Buying Merchandiser, Buying
QC, Buying Technical Team.
Necessary Documentation for Meeting

Required Documents: Matter of Discussion:

• Buyer's details, order information, style • Production schedule, pattern review, size
details. set sample review, inventory details,
• Production file including approved machine layout, QC application, finishing
samples, trims, test reports, wash care and packing processes, among others.
details.
• Inventory of raw materials and
accessories.
Conclusion & Confirmation for Meeting

Confirmation: Record Keeping:

Buying QC checks all attachments and All PP meeting records carefully filed for
agreements. reference.
Both parties sign agreement paper for production Important information shared among key
commencement. employees for successful production.
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 Purpose:
• The pilot run serves to assess production techniques and
quality requirements. It plays a vital role in identifying
potential bottlenecks and critical operations in styles,
informing planning for bulk production.
• Allows for checking production techniques and quality

Pilot Run: requirements.

• Identifies potential bottleneck operations and critical style
Purpose and operations.
Execution:
Execution • During the pilot run, the production setup mirrors bulk
production processes. This includes establishing a stitching line
and conducting production according to the bulk production
plan.
• Production setup mirrors bulk production processes.
• Includes establishing a stitching line and following the bulk
production plan.
Pilot Run: Key Considerations

Key Considerations:
• Several factors must be considered during the pilot run process:
• Processed in the production line, not the sampling section.
• Includes all sizes and colors in the pilot quantity, possibly using jump sizes instead of
all sizes.
• Quality of pilot run pieces may be checked by buyer QA if requested.
• Pilot run pieces are included in the bulk quantity for finishing and shipment.
• Generally, not conducted for small orders.
 Conclusion
• Effective pre-production management is the cornerstone of success in the
apparel industry. By investing in meticulous planning, sample development, and
quality control measures, manufacturers can optimize resources, ensure timely
delivery, and meet market demands. Embracing innovation, sustainability, and
ethical practices is crucial for navigating industry complexities and achieving
sustained growth. In conclusion, mastering the pre-production process is
essential for apparel businesses to thrive in today's competitive landscape and
build enduring partnerships with buyers and consumers.
THANK YOU