Garment Manufacturing Techniques-I Quiz

Course Information

• Course title: Introduction to Garment Manufacturing Techniques-I
• Course code: FASH-103
• Level: 1st semester, B.Des
• Modules included: Introduction to Garment Manufacturing Process
• Instructor: Pratibha Malik

Course Objectives

• Provide an overview of the apparel manufacturing process
• Acquaint students with the processes of producing garments in industry
• Cover the machinery and technologies involved

Course Contents/Syllabus

• Module I: Introduction to Garment Manufacturing Process
  • Covers different departments (sewing, cutting, finishing)
  • Discusses working principles of various departments
  • Outlines different machinery used in each department
  • Comparative analysis of various departments
• Module II: Introduction to Sewing Technology
  • Basic sewing machine components, types and functions
  • Understanding the simple problems in sewing machines and maintenance
  • Introduction to various types of sewing machines and their comparative analyses
• Module III: Sewing Machines
  • Different sewing machines used
  • Descriptions of different bed types and their applications
  • Comparative analysis of different stitch and seam types, including diagrammatic representations (class series diagrams)
• Module IV: Cutting Machines
  • Types of cutting machines (straight knife, band knife, end cutter, auto cutter, die cutter, round knife, drilling machine, notching machine, hot drill)
• Module V: Fusing & Pressing Technology
  • Covers machinery, equipment and process

Credit Structure

• Lecture (L): 2
• Practical (P): -
• Seminar/Workshop/Field Work (SW/FW): 2
• Project/Seminar/Dissertation/Assignment (PSDA): 3
• Total Credit Units: 2

Assessment Scheme

• Continuous Assessment/Internal Assessment (50%):
  • Weightage: Project (15%)
  • Group discussion (10%)
  • Class Test (CT) (10%)
  • Home Assignment (10%)
  • Class Quiz (10%)
  • Attendance (5%)
• End Term Examination (50%)

Module I - Introduction to Garment Manufacturing Process

• Introduction to different departments
  • Sewing, cutting, and finishing departments
  • Different machinery used
  • Comparative analysis
  • Demonstration of machinery in action.

Garment Manufacturing Process

• A sequence of operations from design or sketch to final product
  • Design or sketch
  • Pattern design
  • Sample making
  • Marker making
  • Spreading
  • Cutting
  • Bundling
  • Sewing
  • Pressing
  • Inspection
  • Packing

Departments in Garment Manufacturing Unit

• Merchandising department
• Sampling department
• Fabric store department
• Trims and accessories store department
• Spreading & Cutting department
• Sewing department
• Washing department
• Quality Assurance department
• Finishing & Packaging department
• Maintenance department
• Finance and Accounts department
• HR/Admin department

Garment Manufacturing Processes

• Pre-production: Sampling, Sourcing of raw materials, Approvals, PP meetings
• Production: Cutting, Sewing
• Post-production: Thread trimming, Pressing, Checking, Folding, Packing, Shipment inspection

Sampling

• Critical in the apparel industry
• Buyers place orders after reviewing sample quality
• Purposes
  • Allows buyers to judge production capabilities
  • Provides means of making revisions in bulk production
  • Enables manufacturers to estimate thread and fabric consumption, development of cost quotations

Development Samples

• Proto Sample: Trial sample prepared according to buyer's specification, used to communicate design. Initial design, fabric or style considerations
• FIT Sample: Prepared with actual measurements and specifications, focusing on desired fit
• Salesman Sample: Displayed in retail showrooms to gain customer feedback
• Size Set Sample: Collection of samples made to check sizing/workmanship in various sizes, before mass production.
• Pre-production Sample (PP): Final production sample incorporating all actual fabrics and components
• Top of Production Sample (TOP): Checks whether the factory is following PP sample specification to cross-check for uniformity in production quality
• Shipment Sample: After completion and packaging, to keep records for future reference

Cutting

• First stage of garment manufacturing
• Fabric cut into necessary shapes for pattern pieces of each article
• Involved in the creation of three-dimensional garments by joining pieces via seams
• Includes operations like replication, separation from fabric to create templates then assembly

Cutting Room Process Flow

• Marker (pattern) and cut ratio (size ratio) received
• Marker and plotter making
• Fabric spreading
• Fabric relaxation (if needed)
• Fabric cutting
• Checking cuttings
• Recutting
• Stickering
• Fusing
• Sorting and Bundling
• Stitching
• Printing/embroidery

Spreading and Cutting Flow Process

• Planning, Drawing, and Reproduction of the marker
• Spreading fabric to form a lay
• Cutting fabric
• Preparation for Sewing

Cut Order Planning

• Optimizing cutting process under constraints
• Deciding the combination of markers and lays for a particular order
• Translates customer orders into cutting orders for minimization of total production costs on set deadlines, as well as optimal utilization of labor, equipment, space and fabric

Responsibilities of Cut Order Planning

• Examining incoming orders and piece goods
• Determining volume, size ratio, sectioning procedures
• Determining marker availability and whether new ones are needed
• Developing specifications for marker making and fabric utilization

Marker

• Diagram of a precise arrangement of pattern pieces in a single spread
• Marker Making
  • Process to establish the most efficient layout for pattern pieces given a specific style, fabric and size distribution

Marker Making Requirements

• The need for attention to marker planning in the cutting room due to the substantial portion of cost attributed to cloth used.
• Determining the most efficient layout
• Reducing fabric waste in the cutting room through pattern piece placement in consideration of size, grain line, and style.

Requirements of Marker Planning

• Paying close attention to fabric characteristics in relation to the intended finished garment
• Pattern alignment to fabric's grain (symmetry/asymmetry)
• Design characteristics of the finished garment

Symmetric Fabrics

• No change when the fabric is rotated 180 degrees in the same plane
• Often, solid colored, plain weave fabrics

Asymmetric Fabrics

• Change in appearance when the fabric is rotated 180 degrees.
• This can result in a change in the fabric's color due to differences in light reflection.

Marker Modes

• Nap-either-way (symmetric and non-directional fabrics, considering grain line)
• Nap-one-way (asymmetrical or directional fabrics)
• Nap-up-and-down (directional fabrics where pieces of one size run in one direction and pieces of another size run in the opposite direction)

Marker Efficiency

• Determined by fabric utilization (percentage of total fabric used)
• High efficiency is desired, with low fabric waste

How to Maximize Marker Utilization

• Reduced seam allowances
• Placing patterns 1/2 degree off the grain for plain fabrics
• Fabric width considerations
• Corner rounding
• Reduced spacing between pattern pieces

Spreading

• Superimposing lengths of fabric on a table to create a spread for one marker
• Spread consists of single or multiple plies, the number depending on the fabric type, pieces to be cut, cutting method, and cutting knife height
• Two types: Flat and Stepped spreading

Methods of Fabric Spreading

• Manual method
• Mechanical method (using travelling machine)

Requirements of Fabric Spreading

• Flat fabric
• Correct ply tension
• Fabric ply alignment, directions, and stability
• Minimization of static electricity
• Elimination of fabric flaws
• Easy separation of the cut lay into bundles
• Prevention of plies during cutting
• Avoidance of distortion in the spread
• Matching checks and stripes

Sorting/Bundling

• Sorts pattern pieces by size and design
• Creates bundles. Crucial to avoid mismatched pieces
• Each bundle includes style, size, and specifications, including the attached marker.

Sewing & Assembling

• Parts of clothing are stitched up, creating complete garments in preparation for final delivery
• Sewing station for various operations
• Several workers possibly focus on separate operations such as straight seams, sleeve insets, etc, waist sewing, and buttonhole making.

Inspection

• Checked for faults in finished garments ( open seams, wrong stitching, mismatched threads, missing stitches, raw edges)
• Whole manufacturing process might need to be repeated upon finding inaccuracies

Pressing/Finishing

• Operations applied to adjust the finished exterior of garments via pressure, heat, moisture, and combinations thereof.
• Molding is often incorporated into pressing (creasing or pleating)

Packing

• Garments are bundled, packaged
• Specification details include attached style size, and marker.

Useful Links

• Collection of online resources related to video tutorials and articles regarding different stages of garment manufacturing

Test your understanding of the garment manufacturing process with this quiz focused on the first semester course, Introduction to Garment Manufacturing Techniques-I. It covers essential topics such as sewing, cutting, and finishing departments, along with the machinery involved in producing garments in the industry.