The textile manufacturing process includes certain steps with spinning as the initial one followed by weaving and dyeing, printing, finishing. The garment manufacturing process is the concluding stage of this process carried in production units which results in output as finished products. Garment manufacturing is the process of converting raw material into finished products. It is significant for a textile manufacturing company to carry the pre-production process in an efficient way to attain the targeted required production.

Garment production has its own sequence such as cutting, marking, laying, stitching, spreading, bundling, and checking, and so on. Ready apparel initially begins with the stage of design which ultimately ends up with the finished product. Thus, the garment goes through different processing steps before the shipment.

Now lets us have a look at several stages of the garment manufacturing process

Obtaining the Fabrics:

Firstly, the garments are received from overseas in bulk. The fabric is received in big bolts with cardboard while sometimes fabric might arrive in piles, plastic center tubes or bags. These fabrics are then delivered to giant shipping containers and are unloaded with a forklift. Such factories do have a warehouse to store the fabric between arrival and manufacturing.

Relaxation Fabric:

Relaxation of fabric is very important. It focuses on relaxing the fabric which had already processed from many stages and is further being converted into a finished product. The relaxation process allows the fabric to shrink thus the shrinkage during consumer use is minimized. The garment manufacturing process undertook the relaxation process either manually or mechanically. Manual fabric relaxing includes loading the bolt of fabric on a spinner followed by manually feeding the material by specific equipment that relaxes the fabric as it is pulled through. Mechanical fabric relaxing consists of the same procedure but in an automated manner.

Sometimes the manufactures also include the assurance of quality in this process which meets the standards of the customer. This is performed by manually spot-checking of each bolt of fabric by using a backlit surface; it identifies manufacturing defects such as inconsistency of color or flaws in the fabric.

Spreading, Cutting and Form Layout:

After the relaxation of fabric, it is been further processed for the spreading and cutting of garment. Initially, the fabric is cut into uniform piles which are then either manually or by using the computer-controlled system. The fabric is spread to:

Operators to mark up the fabric defects.

Control the pressure and slack of the fabric during cutting.

Ensure each ply is appropriately aligned on top of others.

The number of plies is spread depending on the fabric type, spreading technique, cutting equipment, and size of the garment order.

After the same garment forms/patterns are laid out on top of the spread, either manually or programmed into an automated cutting system. Finally, the fabric is cut as the shape of garment forms again using either technique.

Laying:

The laying process requires some steps and rules stated below.

Initially, workers lay large pieces which are then arranged into the smaller ones. These smaller pieces could easily fit right in to secure the fabric used in the process. This action will ultimately help economically i.e. will save a lot of money because of simultaneous work lay and hundreds of layers been cut.

There are several rules to ensure that the fabric is properly used and cost-saving.

The length of garments needs to be parallel to the margin of the fabric.

The pattern is placed must be on the right grain.

The parts are arranged on the margin/boundary of the fold.

The laying process is carried on the opposite side of the fabric.

At the time of laying paper patterns, the design of fabric needs to be placed in the exact direction of the fabric. As a result, no one prefers a dress with an upside-down pattern.

The checks and stripes are assured to match the seams.

Marking of the Fabrics:

This process can be conducted manually or by a computerized marking system. Initially, the individual picks out the full-size patterns which are then placed on the marker paper. This could also be cost-effective if conducted properly.

The marking paper is actually a printed paper with signs to indicate the place of every component and ensure if each piece follows required grain lines. Workers apply pins or staples on fabric in order to keep the marker stay at its place. On the other hand, some manufacturers also utilize adhesive paper and provide the heat to seal the top layer.

These makers play an important role to prepare fabric for the cutting procedure. When entering into the cutting room, fabric inlays of approx 100 layers are arranged by a spreading machine. This process is supervised by any required individual to ensure authentic operation.

Cutting of Fabrics:

This is a significant operation held in the cutting room when fabrics are spread and cut into garments. Among all the operations in the cutting room, cutting is the most decisive one, as once the fabric has been cut, hardly anything can be done to rectify serious errors.

Any garment issues generated in the cutting room could merely affect the outcome processed in the sewing room. Assuming all components of fabric the further stage is to shift the cutting room function to the sewing room.

Embroidery and Screen Printing:

Embroidery and screen printing are two processes that occur if demanded by the customer (these are held to offsite facilities). Embroidery is performed by automated equipment. Each production line might include approx 10 and 20 embroidery stations. Customers may request embroidery to apply logos or other embellishments on fabric such as sports t-shirts.

Screen printing is the process including the application of paint-based graphics to the fabric. This is carried by using presses as well as textile dryers. The screen-printed pieces of a garment are dried to set the ink. This process may have different stages of automation or else might largely be finished by manually operated stations. Like embroidery, screen printing is also determined by the customer to print brand and size information in place of affixing tags.

Sewing:

Stitching or sewing is conducted after the cut garments are affixed according to size, pattern color and quantities determined by the sewing units.

The sewing operators attain a bundle of cut fabric and undertake the sewing in the same portion of the fabric, passing that finished section to the further operator.

Quality assurance is conducted at the end of the sewing if any manufacturing defect exists. When required, the garment will be again processed or mended at specific sewing stations. This labor-intensive process transforms pieces of garments into designer ones.

Stitching is done as per the choice of the customer. Computerized sewing machines are utilized to end up the sewing operation.

Checking and Laundry:

Checking is done at the end of the sewing line. Workers need to ensure correct supervision of garment without any manufacturing defects.

The clothing manufacturer has a specific standard of garment quality. This process minimizes the ratio of garments refused by customers. At the time of checking, workers can easily spot stains, spots on the garments due to the previous processes. Normally the spots or stains occur because of markers in the previous stages. Thus, all fabrics are taken to the laundry within the factory.

Fusing and Pressing:

Fusing and pressing are two significant stages that decide the final appearance of the garments manufacturing process. After a garment is completely sewed and assembled, it is shifted to the ironing section for final pressing. While fussing applies the foundation, pressing conducts the final seal on the garments. Hand irons with vacuum press table, carousel machines, scissors press, and steam dolly are the machinery used to complete fussing and pressing.

PACKAGING AND SHIPPING:

In the last steps garments are folded, tagged, sized, and packed according to customer specifications. In the end, garments are arranged in the cardboard boxes and further shipped to client distribution units. When a boxed or hanging garment has to be transported in large quantity the boxes are packed into cartons which could be sealed by paper or plastic Manual.

The above process surely makes clear about how the garment manufacturing process is conducted in production units being processed individually at various stages. Garment manufacturing is different from others such as spinning, dyeing, and weaving in the textile manufacturing process, as a result, it actually provides us the finished products instead of semi-finished ones.