Apparel manufacturing:
Preparatory process
Soft winding
↓
Batching
↓
Batch loaded
↓
Demineralization (50˚C, 20 min; PH=4.5)
↓
Scouring & bleaching (100˚C×40 min.)
↓
Drain
↓
Rinse
↓
Drain
↓
Neutralization with acid (50°C ×20 min)
↓
Hot Wash with peroxide killer (60˚C,20 min.)
↓
Drain
↓
Dyeing
↓
Leveling agent & Salt (60° × 20 min; PH=6)
↓
Color dosing (60°C×20 min.)
↓
Run time = 10 min. (60°C)
↓
Color migration (80°C × 20 min.)
↓
Cooling (60°C)
↓
Level Check
↓
Soda dosing (60°C×30 min.)
↓
Dyeing run (Dark-60°C×60 min;Medium-60°C×40 min;Light-60°C×
30 min)
↓
Dyeing sample check
↓
(If Ok)
↓
Drain
↓
After-treatment
↓
Rinse (with cold Water)
↓
Neutralization after dyeing (50°C×20 min.)
↓
Drain
↓
Soaping (Hot wash)
↓
Drain
↓
Rinse
↓
Add finishing chemical(60°C×20 min)
↓
Drain
↓
Quality:
Quality is a relative term. It means customer needs is to be satisfied. Quality is of prime importance in any aspect of business specially of export oriented products. Customers demand and expect value for money. As producers of apparel there must be a constant endeavor to produce work of good quality. Process flow chart of quality section of garment is given below.
Sample comments follow-up measurement
↓
Pattern grading
↓
Pattern through to cutting section
↓
Fabric inspection (GSM, color shade etc)
↓
Fabric Ok
↓
Lay check
↓
Print check
↓
Line check
↓
Sewing output check
↓
After remove if have
↓
Finishing (ironing)
↓
Main check ( size measurement)
↓
Size wise measurement
↓
Get up checking
↓
4 point measurement
↓
Packing
↓
Hand tag follows up
Check the batch information compare with the fabrics information’s.
↓
Match the shade with the bulk production fabrics.
↓
Check the running shade among the roll or roll to roll.( as per guide line).
↓
Check the GSM, DIA and hand feel.(as guide line).
↓
Check the shrinkage (as guide line).
↓
Check the any marks like sinker, needle, DIA, crease mark etc.
↓
Check other faults.
↓
Make report, Discussed with the respective persons to take actions.
↓
Make grading as guide line.
↓
Delivery the okay goods to the Stores.
↓
Reject goods send to MIS store.
↓
Follow up.
Unload Garment is a basic need of human being. It's manufacturing process is complicated. Garment/Apparel manufacturing processing depends on some steps and techniques. It starts from order receiving and will be end to dispatching shipment of the finished garments. A process flow chart helps to understand how raw materials are moved from one process to another process until raw materials are transformed into the desired product (garments).
Yarn Dyeing:
Yarn dyeing is a special type of dyeing process. This dyeing process is slightly difference from woven or knit dyeing. Dyed yarns are used for making stripe knit or woven fabrics or solid dyed yarn fabric or in sweater manufacturing. Yarn can dye in two form, package or hank form. Flowchart of yarn dyeing can be divided into three stages. Preparatory process, Dyeing and After-treatment process.
Yarn dyeing is a special type of dyeing process. This dyeing process is slightly difference from woven or knit dyeing. Dyed yarns are used for making stripe knit or woven fabrics or solid dyed yarn fabric or in sweater manufacturing. Yarn can dye in two form, package or hank form. Flowchart of yarn dyeing can be divided into three stages. Preparatory process, Dyeing and After-treatment process.
 |
| Yarn dyeing in package form |
Flow Chart of Yarn Dyeing
Preparatory process
Soft winding
↓
Batching
↓
Batch loaded
↓
Demineralization (50˚C, 20 min; PH=4.5)
↓
Scouring & bleaching (100˚C×40 min.)
↓
Drain
↓
Rinse
↓
Drain
↓
Neutralization with acid (50°C ×20 min)
↓
Hot Wash with peroxide killer (60˚C,20 min.)
↓
Drain
↓
Dyeing
↓
Leveling agent & Salt (60° × 20 min; PH=6)
↓
Color dosing (60°C×20 min.)
↓
Run time = 10 min. (60°C)
↓
Color migration (80°C × 20 min.)
↓
Cooling (60°C)
↓
Level Check
↓
Soda dosing (60°C×30 min.)
↓
Dyeing run (Dark-60°C×60 min;Medium-60°C×40 min;Light-60°C×
30 min)
↓
Dyeing sample check
↓
(If Ok)
↓
Drain
↓
After-treatment
↓
Rinse (with cold Water)
↓
Neutralization after dyeing (50°C×20 min.)
↓
Drain
↓
Soaping (Hot wash)
↓
Drain
↓
Rinse
↓
Add finishing chemical(60°C×20 min)
↓
Drain
↓
Quality:
Quality is a relative term. It means customer needs is to be satisfied. Quality is of prime importance in any aspect of business specially of export oriented products. Customers demand and expect value for money. As producers of apparel there must be a constant endeavor to produce work of good quality. Process flow chart of quality section of garment is given below.
 |
| Quality section in garment industry |
Working Sequence of Quality Section:
Sample comments follow-up measurement
↓
Pattern grading
↓
Pattern through to cutting section
↓
Fabric inspection (GSM, color shade etc)
↓
Fabric Ok
↓
Lay check
↓
Print check
↓
Line check
↓
Sewing output check
↓
After remove if have
↓
Finishing (ironing)
↓
Main check ( size measurement)
↓
Size wise measurement
↓
Get up checking
↓
4 point measurement
↓
Packing
↓
Hand tag follows up
Garments Quality Control:
Quality is a relative term. It means customer needs is to be satisfied. Quality is of prime importance in any aspect of business. In the competitive world no alternative of quality. Worlds trend is now quality not quantity. In the apparel business severely maintain quality of products. In this case, buyers satisfaction is the primary and basic goal. For maintaining quality of garments, quality is strictly control in garments industry. In this article, I will give a flowchart of garments quality control.
Quality is a relative term. It means customer needs is to be satisfied. Quality is of prime importance in any aspect of business. In the competitive world no alternative of quality. Worlds trend is now quality not quantity. In the apparel business severely maintain quality of products. In this case, buyers satisfaction is the primary and basic goal. For maintaining quality of garments, quality is strictly control in garments industry. In this article, I will give a flowchart of garments quality control.
 |
| Quality Control System in Garments Industry |
Flow Chart of Quality Control System in Garments Industry:
Check the batch information compare with the fabrics information’s.
↓
Match the shade with the bulk production fabrics.
↓
Check the running shade among the roll or roll to roll.( as per guide line).
↓
Check the GSM, DIA and hand feel.(as guide line).
↓
Check the shrinkage (as guide line).
↓
Check the any marks like sinker, needle, DIA, crease mark etc.
↓
Check other faults.
↓
Make report, Discussed with the respective persons to take actions.
↓
Make grading as guide line.
↓
Delivery the okay goods to the Stores.
↓
Reject goods send to MIS store.
↓
Follow up.
Knitting:
There are three types of fabric manufacturing process. They are weaving, knitting and non-weaving. Knitted fabric produced by loop forming. Such type of fabric huge demand in present world. For manufacturing of knitted fabric, process flow chart of knitting technology are given below.
Yarn in package form
↓
Place the yarn package in the creel
↓
Feeding the yarn
↓
Set the m/c as per design & GSM
↓
Knitting
↓
Withdraw the roll fabric and weighting
↓
Roll marking
↓
Inspection
↓
Numbering
There are three types of fabric manufacturing process. They are weaving, knitting and non-weaving. Knitted fabric produced by loop forming. Such type of fabric huge demand in present world. For manufacturing of knitted fabric, process flow chart of knitting technology are given below.
 |
| Circular Knitting |
Process Flow Chart for Knitting
Yarn in package form
↓
Place the yarn package in the creel
↓
Feeding the yarn
↓
Set the m/c as per design & GSM
↓
Knitting
↓
Withdraw the roll fabric and weighting
↓
Roll marking
↓
Inspection
↓
Numbering
↓
Dispatching
Dispatching
Unload Garment is a basic need of human being. It's manufacturing process is complicated. Garment/Apparel manufacturing processing depends on some steps and techniques. It starts from order receiving and will be end to dispatching shipment of the finished garments. A process flow chart helps to understand how raw materials are moved from one process to another process until raw materials are transformed into the desired product (garments).
 |
| Garments manufacturing |
Process Flow Chart of Garment Manufacturing
Design/sketch
↓
Basic block
↓
Working pattern
↓
Sample making
↓
Basic manufacturing difference
↓
Approved sample
↓
Costing
↓
Production pattern
↓
Grading
↓
Marker making
↓
Fabric spreading
↓
Cutting
↓
Sorting or bundling
↓
Sewing
↓
Ironing and finishing
↓
Final inspection
↓
Packing
↓
Cartooning
↓
Send to buyer
↓
Basic block
↓
Working pattern
↓
Sample making
↓
Basic manufacturing difference
↓
Approved sample
↓
Costing
↓
Production pattern
↓
Grading
↓
Marker making
↓
Fabric spreading
↓
Cutting
↓
Sorting or bundling
↓
Sewing
↓
Ironing and finishing
↓
Final inspection
↓
Packing
↓
Cartooning
↓
Send to buyer
In details apparel manufacturing sequence are given below:
Operation
|
Job
|
Method
| ||
01. Design/sketch
|
It is given by buyers to manufacturers containing sketches including measurements of the style
|
Manual/computerized
| ||
02. Basic block
|
Without any allowance
|
Manual/computerized
| ||
03. Working pattern
|
Assimilating of diagram of net dimension on paper each and individual part which is called pattern and when we move with it throughout the whole manufacturing processes. We term it working pattern.
|
Manual/computerized
|
Manual/computerized
| |
04. Sample making
|
After getting all the speech the sample is made and sent to the buyers for approval to rectify the faults.
|
Manual
| ||
05. Basic manufacturing difference
|
The critical path is identified i.e the problem during the several operations.
|
Manual
| ||
06. Approved sample
|
After rectify the faults, sample is again sent to buyers. If it is ok, than it is called approved sample.
|
Manual
| ||
O7. Costing
|
|
Manual
| ||
08. Production pattern
|
Add allowance with net dimension.
|
Manual/computerized
| ||
09. Grading
|
It is done according to different size.
|
Manual/computerized
| ||
10. Marker making
|
Maker is a thin paper which contains all the components of all sizes of a particular style.
|
Manual/computerized
| ||
11. Fabric spreading
|
Fabric is spreaded in lay form.
|
Manual/computerized
| ||
12. Cutting
|
To cut fabric according to the dimension by special types of cutter.
|
Manual/computerized
| ||
13. Sorting or bundling
|
Sorting out the component according to size and for each size make individual bundle.
|
Manual
| ||
14. Sewing
|
Sewing is done by different types of machines by the operation. Quality inspection is also done in that time
|
Manual
| ||
15. Ironing and finishing
|
Garments are treated by steam. Also several finishing processes are done for example extra loose thread cutting.
|
Manual
| ||
16. Final inspection
|
Should meet specs given by buyer.
|
Manual
| ||
17. Packing
|
Poly packing.
|
Manual
| ||
18. Cartooning
|
After packing the garments are placed in a hard paper box .for export so as to minimize damage. The cartoons contain all the information over the box according to buyer specs.
|
Manual
| ||
19. Send to buyer
|
If everything is ok, it is sent to the buyer.
|
Manual
| ||
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