Flow Chart of Garments Manufacturing

Process
Garments Manufacturing:
A complete garment has to face several processes from its order receiving to shipment. During garments
manufacturing, a process flow chart must be needed to complete an order easily. Also a process flow chart
helps to understand a garment manufacturing method that how the raw materials are converted into the
wearable garments.

Flow Chart of Garments Manufacturing Process / Technology:

A basic garment manufacturing flow chart is presented in the below:

Design

↓
Pattern Making

↓
Fit Sample Making

↓
Production Pattern Making

↓
Grading

↓
Marker Making

↓
Fabric Spreading

↓
Fabric Cutting

↓
Cutting Parts Sorting or Bundling

↓
Sewing
↓
Garments Inspection

↓
Garments Ironing and Finishing

↓
Final Inspection

↓
Garments Packing

↓
Cartooning

↓
Shipment

Each process of garments manufacturing flow chart is discussed in the below with the details:

1. Design:
Design is provided by the buyer. After placing an order buyer send the technical sheet and art-work of an
order to the merchandiser. This process is done by both manually or by using computer.
2. Pattern Making:
By following technical sheet and art-work, pattern of each garment style should be made. It’s done by
both manually and by using computerized method.
3. Fit Sample Making:
The main target of making a fit sample is to follow the details instruction about that garments style. After
making it’s sent to the buyer to rectify. It’s done by manually.
4. Production Pattern Making:
For bulk production, allowance added here with net dimension. Production Pattern Making is done by
both manually and by using computer.
5. Grading:
During an order confirmation, the buyer suggests about the size ratio of that order. So that order should
be graded according to the buyer’s instruction. Grading is done by manually or by using computer.
6. Marker Making:
Marker is a very thin paper which contains all the parts of a particular garment. To make the cutting
process easy, it’s must be needed. Marker making process can be done by both manually and by using
computer.
7. Fabric Spreading:
To cut the fabric properly fabric is spread in lay form. Fabric Spreading is done by manually or by using
computerized method.
8. Fabric Cutting:
Fabrics have to cut here according to marker of garments. Fabric Cutting process is done by using
manual method or computerized method.
9. Cutting Parts Sorting or Bundling:
Here, cutting parts have to sort out or make bundling to send these easily into the next process. This
process is done by manually.
10. Sewing:
All the parts of a garment are joined here to make a complete garment. Sewing process is done by
manually.
11. Garments Inspection:
After completing sewing, inspection should be done here to make fault free garments. Garments
Inspection is done by using manual method.
12. Garments Ironing and Finishing:
Here garments are treated by steam; also required finishing should be completed here. This process is
done by using manual method.
13. Final Inspection:
Finally the complete garments are inspected here according to the buyer’s specification. Final Inspection
is done by manual method.
14. Garments Packing:
Complete garments are packed here by using buyers instructed poly bag. Garments packing are done by
using manual method.
15. Cartooning:
To minimize the damages of garments, all the garments have to cartooned by maintaining buyers
instruction. This process is done by manually.
16. Shipment:
After completing all the required processes it’s finally send to the buyer.
Sewing:
Sewing is an important department in garments manufacturing industry. All the parts of a garment are joined
here by making stitch with the help of needle and thread. Where, sewing process flow chart helps to make
a complete garment easily. By maintaining sewing process flow chart, an order can be completed in timely.

Process Flow Chart for Garments Sewing Department:

Product analysis

↓
Set up target for production

↓
Set up machine layout on the basis of target

↓
Set up operator layout on the basis of target

↓
QC check of product

↓
Line balancing

↓
Line setup

↓
Distribution all the processes

↓
Cutting parts received section

↓
Cutting parts distribution to the operator and helper

↓
Complete parts making individually

↓
Online QC check

↓
Online quality audit
↓
Counting output and checking with the target

↓
Final quality check (for each Garment)

All the process sequence of garments sewing department are discussed in the below:

S/L Process Job

01 Product analysis In which way, a product have to sew, it’s decided

here.
02 Set up target for production Have to set a target for production on the basis of
shipping schedule.
03 Set up machine layout Have to prepare machine setup layout on the basis of
on the basis of target daily target quantity.
04 Set up operator layout on Prepare operator layout setup on the basis of machine
the basis of target quantity.
05 QC check of product Each garment must have to fulfill its right quality. So,
product checking must be needed by QC.
06 Line balancing Line balancing is a tool used for production line to
capacitate the flow line of production.
07 Line setup Line setup must be needed to achieve healthy
production.
08 Distribution all the All the processes of sewing must be distributed to the
processes right person to avoid the damage of garments.
09 Cutting parts received A section, which received the cutting parts from the
section cutting department.
10 Cutting parts distribution to All the cutting parts should be distributed to the
the operator and helper operator and helper after receiving those from cutting
department.
11 Complete parts making By joining all the parts, a complete garment has to
individually make here individually.
12 Online QC check During running of garments sewing, online QC check
must be needed to make fault free garments.
13 Online quality audit An online quality audit must be needed here to show
the buyer actual fault free product making
process.
14 Counting output and Comparing with target quantity, all the output
checking with the target garments should be counted here to make sure
achieving the target quantity.
15 Final quality check In this section, all the output garments are checked
(for each Garment) finally by maintaining one by one method to provide
fault free garments into the finishing department.

Cutting:
Cutting is one of the major process in garments manufacturing. Here garments parts are cutting
according to the pattern. In garments cutting department, a process flow chart have to maintained to send
the right measurement parts in the next process for making quality garments. As its importance in
garments manufacturing, a process flow chart for garments cutting department is presented in this article.

Process Flow Chart of Fabric Cutting Department:

Pattern received from pattern department

↓
Cutting ratio received from merchandiser

↓
Marker making

↓
Fabric received from the store

↓
Fabric Checking

↓
Fabric Spreading

↓
Marker placing on to the lay

↓
Cutting the fabric

↓
Numbering

↓
Checking

↓
Sorting and Bundling
↓
Send to the sewing department

Each process of garments cutting flow chart is discussed shortly in the below table:

S/L Process Job

01 Pattern received from At first you have to received different sizes pattern for
pattern department each style garments from the pattern department.
02 Garments cutting ratio Cutting ratio for each style garments should be
received from received from merchandiser
merchandiser
03 Marker making To complete cutting process in easy way, you have to
make marker for each style garments.
04 Fabric received from the At the mean time, you have to received fabrics from the
store store for each style of garments.
05 Fabric Checking Here, fabrics have to checked and confirm the shade
variation free fabrics in cutting table.
06 Fabric Spreading When the above process is completed, then you have to
spread the fabric with correct lay height and ply
tension.
07 Marker placing on to the After that, marker have to placed on the top layer of the
lay lay.
08 Cutting the fabric Here, fabrics have to cut by maintaining marker.
09 Numbering After cutting the fabrics, each parts of different style
fabrics should be numbered to avoid mixing with the
others style fabric parts.
10 Checking Checking the cutting fabrics accurately by comparing
with its marker.
11 Sorting and Bundling Cutting parts should be sorting and bundling here to
send easy into the next process.
12 Send to the next process. Cutting fabric parts have to sent into next process
(where required) like printing, Embroidery, sewing etc.

Methods of Fabric Cutting:

In garments industry, there are two available cutting methods, these are-

1. Manual Method,

2. Computerized Method.

Those are discussed in the below:

1. Manual Fabric Cutting Method:

Here cutting process is done by using knife, scissor, drill etc. Knife is placed in the head of the cutting
machine. Manual method is the most used cutting method in garments industry.

Manual cutting method can be done by using the following equipments:

 Round knife,

 Band Knife,
 Straight Knife,

 Scissor,

 Die-cutting,

 Drill.

Advantage of Manual Cutting Method:

1. Easy process of cutting.

2. Educated man power is not required.

3. Low cost knife is enough here to cut the fabric.

4. Low maintenance cost.

Disadvantage of Manual Cutting Method:

1. Slow process.

2. Not suitable for large scale production.

3. Cutting speed cannot be controlled.

4. Intensity of accident is very high.

5. Higher labor cost than computerized cutting method.

2. Computerized Fabric Cutting Method:

In modern garments manufacturing industry, computerized cutting method becomes so much popular in
day by day due its higher production and less time consuming efficiency. Here all programmes are loaded
into the computer and the computer performs all the activities which are loaded.

Computerized Cutting method can be done by using following equipments:

 Straight knife cutting,

 Water jet cutting,

 Laser beam cutting,

 Plasma torch cutting.

Advantage of Computerized Cutting Method:

1. Very much effective cutting by computer controlled system.

2. Very fast cutting operation.

3. Suitable for large scale production.

4. Cutting speed can be controlled.

5. Intensity of accident is very low.

6. No need any marker.

7. Fabrics can be cut 7-8 times higher than manual cutting method.

8. Low labor cost.

Disadvantage of Computerized Cutting Method:

1. Higher maintenance cost.

2. Skilled and educated manpower is required.

3. So much expensive machine.

4. If correct disc is not loaded in the computer, then error will be indicated.

Types of Denim Fabric Used in Garments

Manufacturing

Denim Fabric:
Denim is a twill weave woven and 100% cotton fabric which is consists of different colors of warp and weft
yarn. In denim fabric, one color is predominant on the fabric surface. Denim is a common raw material
for garments manufacturing. Usually denim fabric is produced by using cotton though sometimes hemp
denim is also available. Denim fabrics are normally used for making jeans, work clothes as well as
casings for organic futons and pillows.

Denim Fabric Manufacturing Method:

Denim fabric is a rugged cotton twill textile, where the weft passes under two or more warp fibers,
producing the familiar diagonal ribbing identifiable on the reverse of the fabric.

Properties of Denim Fabric:

Denim fabric follows some properties; those are mentioned in the following:

1. Denim fabric creases easily.

2. It is very strong and durable.

3. It is feeling hard during wearing.

4. It is used for long time wearing.

5. It resists tears and snags.

Types of Denim Fabric:
There are mainly eight types of denim fabric, those ares-

1. Colored denim,

2. Bubble gum denim,

3. Denim from fox fiber,

4. Crushed denim,

5. Vintage denim,

6. Ecru denim,

7. Marble denim,

8. Reverse denim.

All the above denim fabric types are discussed in the below:

1. Colored denim:
Colored denim fabrics are woven, manufacturing with dyed yarn either warp or weft. This kind of fabric
can be obtained by piece dyeing process.
2. Bubble gum denim:
Bubble gum denim fabric is lycra containing denim, that has between 35 to 50% lycra or stretch.
3. Denim from fox fiber:
This kind of denim fabric is manufactured by colored cotton fiber that grows naturally developed and
patented by California cotton breeder sally fox.
4. Crushed denim:
In Crushed denim fabrics, textured effect achieved through a special fabric construction coupled with wet
processing, where the effect can also be improved by using stone and bleach. This kind of denim fabric is
woven with an over twist weft yarn.
5. Vintage denim:
For achieving old and worn outlook, a denim treatment that applies heavy stone wash or a cellulose
enzyme wash with bleach or without bleach is called vintage denim.
6. Ecru denim:
Ecru denim fabric is that, which is not having any dyed yarn, contains only grey yarn in warp and weft.
7. Marble denim:
Marble denim has another name is acid wash. If the fabric is strongly bleached then it is called marble
denim.
8. Reverse denim:
Reverse denim fabric is that, where the face side and reverse side look alike.
Difference Between Denim and Jeans
Introduction:
It’s a tough question for anyone when you will ask someone to differentiate between denim and jeans. In
some parts of the world, the word “denim” is used interchangeably with the word “jeans” in such a manner
that people refer to jeans as denim. Denim and jeans are two different things, which are related with one
another. There are vast differences between those two words. To remove the confusion about these today
I will present the difference between denim and jeans in this article.

Jeans:
Jeans is one type of garment, which is normally used by the all aged people today. For the first time, jeans
garments introduced by Levi Strauss as a copper riveted cotton trouser in the second half of the 19th
century. Today jeans have achieved too much popularity among the people due to its wearing comfort
ability. Jeans is such types of garments which can be used by any aged people at any situation. Modern
students cannot live without the basic 5 pocket jeans, as it’s seen that, their wardrobes are full with different
pairs of jeans for all the occasions. Blue is the color of jeans that provides unique identity of jeans, though
now a day, different colored jeans also produced.

The main advantages of using jeans are in the following-

1. It can be worn without pressing.

2. No need frequently jeans garments washing than other garments.

3. Fashionable garments,

4. Long lasting.

Denim:
Denim is one kinds of fabric which can be made from 100% cotton twill or Stretch twill. Denim is a woven
fabric which contains warp yarn that is blue cotton and a filling yarn that is white cotton helping to create
heavy twill that has diagonal running parallel lines. Denim fabric is used in all over the world for making
jeans, jackets, shirts, bags, purses, and many other accessories for men and women of all ages.

Difference between Denim and Jeans:

SL No. Denim Jeans

01 Denim is one kinds of fabric name Jeans is one type of garment which is
which can be made from 100% cotton made by using denim fabric.
twill or Stretch twill.
02 Denim is a fashionable fabric, by which Jeans is only a particular style of
different types of garments style can be garments.
produced.
03 Denim can be defined either jackets, Jeans is specially defined at denim
skirts, pants, shorts etc. pants.
04 Denim is used not only for making pants Jeans is such type of garments which is
but also for jackets, skirts, shorts etc. made only from denim fabric.
05 All denims are not jeans. All jeans are denim.

Flow Chart of Denim Manufacturing Process

Introduction:
In this fashionable era, young generation is highly dependent on denim based garments. It’s seen that their
wardrobes are full with different types of garments which are made by using denim fabric. Normally denim
is a twill weave woven and 100% cotton fabric which contains dyed warp yarn and grey weft yarn. During
denim fabric manufacturing, a process flow-chart should maintain to facilitate the fabric manufacturing
process which is discussed in this article.

Denim Manufacturing Process

Flowchart of Denim Manufacturing Process:

Yarn collection from spinning factory
↓
Warping
↓
Yarn dyeing
↓
Weaving
↓
Singeing
↓
Equalizing or Heat setting
↓
Finishing
↓
Inspection
↓
Folding & Packing
↓
Delivery

All the above processes are discussed in the following table:

SL/No. Process Procedure

01 Yarn collection from According to required types of denim fabric, yarn should collect
spinning factory from the spinning factory. Denim fabric can be crushed denim,
vintage denim and reverse denim etc.

02 Warping Here, warping is done to arrange a convenient number of warp

yarns of related length so that can be collect on a single warp
beam as a continuous sheet of yarns which can be used for next
processes.

03 Yarn dyeing In this process, scouring, washing, dyeing and drying is done. It
should be noted that, only warp yarns have needed to dye.

04 Weaving Weaving is done here by using warp yarn (dyed yarn) and weft
yarn (grey yarn). Here different types of weave design has
followed such as 2/1 twill weave, broken twill, reverse twill,
zig-zag twill etc. sometimes fancy design also used for producing
fashionable fabric.

05 Singeing Singeing is done here to obtain a clean fabric surface which

allows the structure of the fabric to be clearly seen.

06 Equalizing or Heat Equalizing or heat setting is done here to control fabric

setting shrinkage percentage. Special types of weft yarn are heated
here so that it can’t create high shrinkage during garments
manufacturing process.

07 Finishing In case of denim finishing, sanforizing process is used.

08 Inspection Finally inspection is done here, if found any problem, taken

necessary steps to solve that.

09 Folding & After inspecting denim fabrics, folding and packing is done here
Packing to deliver the goods.

10 Delivery Finally all the goods are sent to the buyer.

Flow Chart of Denim Washing Process

Denim Washing:
Denim washing is the aesthetic finish, which is given to the denim fabric to enhance the appeal and to
provide strength. In case of denim washing, several wash effects can be produced such as- color fading
with or without patchiness, seam puckering, de-pilling, crinkles, hairiness etc. But denim washing follows a
process flow-chart, by which all the mentioned effects can be achieved easily. As its importance in garments
washing, the whole process flowchart of denim washing have discussed in this article.

Process Flowchart of Denim Washing:

Garments received
↓
Dry process
↓
Send to wet process
↓
Garments loading in washing machine
↓
De-size
↓
Enzyme
↓
Bleaching (If needed)
↓
Neutralization
↓
Extracting
↓
Drying
↓
P.P spray
↓
Neutralization
↓
Tinting
↓
Softener
↓
Extracting
↓
Drying
↓
3D
↓
Curing
↓
Q.C check
↓
Delivery
The above all processes are discussed in the below table:
SL No. Process Procedure

01 Garments received Firstly, denim garments should receive from the sewing
department.
02 Dry process If garments needed any types of dry process (Hand-sand, whisker,
tacking etc), then it’s sent to the dry process section to do that.

03 Send to wet process After completing required dry processes, garments sent to the wet
process section.

04 Garments loading in Garments are loaded into washing machine to complete the
washing machine garments washing processes followed by the buyers approved
wash reference.

05 De-size De-sizing process is done here by using de-size chemical to remove

size material from the garments.

06 Enzyme According to buyers provided wash reference, enzyme washing

process is done here by using enzyme chemical (Acid enzyme or
Neutral enzyme).

07 Bleaching According to wash reference, If bleaching process is needed to

match with the desired shade then it’s done here by using
bleaching chemical (K.C.I or Japani Bleach).

08 Neutralization Bleaching chemical should be neutral here by using sodium meta

bi-sulphite or sodium hypo. Each chemical choice depends on the
instant situation of garments.

09 Extracting Here, garments are extracted by using hydro extractor.

10 Drying Garments are dried here by using gas dryer or steam dryer.

11 P.P spray According to wash instruction, if garments have needed P.P effect,
then P.P should be done here by using required chemical.

12 Neutralization Here, P.P chemical have to neutral by using sodium meta bi-
sulphite.

13 Tinting Sometimes, tinting is needed for matching with the required shade.

14 Softener This process is done here by using softening chemical. Its may be
cationic or non-ionic softener.

15 Extracting Garments are extracted here by using hydro extractor machine.

16 Drying Here, all the garments are dried by using gas dryer or steam dryer.

17 3D According to buyers approved wash reference, if garments needed

3D effect then 3D process is done here.

18 Curing After applying 3D process, all the garments are cured here by using
woven machine.
19 Q.C check All the garments are checked here by maintaining buyers approved
wash reference sample or shade band.

20 Delivery Finally garments sent to the finishing department.