The machine in the picture is a circular knitting machine which makes t-shirt fabric. It is just as important as sewing. Fabric production is the longest step in apparel manufacturing lead time. There are many steps which I outline below that you should be familiar with if you are going to work with a factory to improve your garment production lead time.
When fabric arrives at the factory it arrives in rolls. When the fabric is “rolled up” it stretches beyond its normal dimensions. This is more applicable to knit fabric than woven fabric. To remedy this, a factory must relax knit fabric for at least 24 hours before cutting. Relaxing means they unroll it and set it out on a crate bunched up loosely. To check their competency level, ask them, “do you relax the fabric for 48 hours?” A good factory will answer confidently, “no, we only relax the fabric for 24 hours.” Remember, for woven fabric, relaxing is not an issue. This plays role in garment manufacturing lead time.
For 5,000 pieces, you would need approximately 6,000 meters of fabric, which would take 16 days to produce.
Once the fabric is in house, the factory can make a pre-production sample. The sample is usually size medium. This should take a maximum of three days. They will send you the sample and you need to either approve it or ask for alterations. Sending the samples via DHL takes at least 2 days each way. Assume you turn around the comments in a day. You are looking at a week for fit samples to be processed.
The basic steps of production are:
Fabric Cutting – 2 Days; 2,500 pieces per day
Sewing – 6 Days; Average 900 pieces per day
QC – On going
Ironing – 2 Days; 2,500 pieces per day
Folding – 3 Days; 1,666 pieces per day
Packing – 1 Day
In general, these are the components in garment manufacturing lead time.
First the fabric is laid out on the table and the marker is laid on top of the fabric. Cutter staff cut along the marker lines. The result is stacks of panels. A panel might be the right sleeve or front chest, for example. The panel stacks are bundled together and sent to the sewing lines.
Often printing and/or embroidery needs to be done before sewing. So, special care is taken to separate the sleeve, for example, to be sent away to the embroidery supplier. Hopefully the embroidery sub-contractor is not backlogged or else the embroidery step could take a week when in fact the job is finished in one day.
Once the line is ready, the line leader will assign sewing operations and the first couple of garments are made. It takes the line 2 – 3 days to reach maximum capacity and ensure the quality control. This is called “setting up the line”. After that, it’s all about improving the line efficiency and constantly checking quality. Generally speaking, one sewing line can produce 900 garments per day.
Quality control is done in line and there is a separate quality control section between the lines and ironing. Any defective garments are either fixed or removed from production.
Ironing happens after the final QC and before folding.
Folding includes adding accessories like tissue, silica gel bags, and hang tags before the folded garment is inserted into poly-bags and put into the carton box. Garment manufacturing lead time includes many small steps. The more you understand the more you can find ways to speed things up.
In Summary: The whole process of garment manufacturing lead time in Vietnam takes anywhere from 60 to 120 days depending on the complexity of the garment AND other orders the factory is doing. The step that takes the longest is fabric production. The second most time consuming step is printing or embroidery because usually the factory has to send the panels out for printing and embroidery. What you need to keep in mind is that the TOTAL time it takes to get your garments to YOUR warehouse is production lead-time PLUS shipping time. Best-case scenario is 60 days production time and 30 days shipping. Producing in Vietnam means that you won’t see your garments for at least 90 days. That is the nuts and bolts of garment manufacturing lead time in Vietnam.
I wrote this book for you to be able to make your tech packs and understand how hard it is. If you have well done tech packs than half the battle is done.
TABLE OF CONTENTS
MY BEST ADVICE
VALUE OF A TECH PACK
27 DECISION POINTS
BILL OF MATERIALS
EXAMPLE TECH PACKS
TECH PACK SOFTWARE
Contact me today!
1. Which styles do you want to manufacture first?
2. Do you have tech packs?
3. Do you have any special factory requirements?
4. Have you produced before? If yes, then in what country?
5. What quantity per style per color do you order?
6. Does your company have a website?
7. Do you want to work with an agent or directly with the factory?
8. Do you plan to visit Vietnam?
Fashion Start-up Consultant
Ho Chi Minh City, Vietnam
Author and Dad