Apparel Manufacturing Industry Garments | Apparel | Leather Manufacturing

Garments | Apparel |Leather Manufacturing Industry

SERVUNTO™ - ERP On Device, Presents End-to-End Software Solution for Textile Industry.

There are various processes involved in the manufacturing of apparel/garment. Ready to use apparel or garment manufacturing involves many processing steps, beginning with the idea or design concept, customer requirement and ending with the finished product.

Some of the processes involved in apparel manufacturing include – Design/Sketch, Sampling, Costing, Production Planning, Maker Making, Fabric Spreading, Cutting, Sewing, Stitching, Thread Trimmed, Washing, Finishing, Ironing, Packing, Folding, Final Inspection and Dispatch.

A brief overview of few processses may be put as follows: -


The first step is designing the sketch for the dresses that should be prepared. The designer first draws several rough sketches in the sketchbook or in the CAD/CAM by their own creativity or as per the buyer’s requirements.


Sampling is the second process in the garment manufacturing process. According to the design made by the designer the sample garment is manufactured and is sent to the buyer to rectify. This stage is also known as the product development stage.


Business is all about making profit. So the correct costing of the product before order finalization is very important. The cost of the garment is the cumulative cost of raw material, labour cost, factory margin, office cost, depreciation cost of the machine and taxes etc.

Production Planning

Subsequent to receiving the order, factory plans for when to buy the raw material required for the order. Raw material like fabrics, sewing threads, packing material, tags, and other required accessories. The factory must plan for the timelines like when to start cutting, when to submit a preproduction sample when to finish sewing, and finishing, final inspection date, and shipment date. In production planning stage job responsibility for different processes is well defined.

Production planning and control department is one of the important departments for the apparel manufacturing company.

Vital steps involved in Production Planning are as follows:-

Job | Task Scheduling: Preparation of time and action sheet for each order from order receiving to shipment. The task schedule contains list of tasks to be processed for the styles. Against each tasks planner mentions when to start a task and what is dead line for that task. Name of responsible person /department for the job is listed. For example, scheduling planned cut date (PCD), production line loading date etc.

Material Resource Planning (Inventory): Preparation of Material requirement sheet according to sample product and buyer specification sheet. This is usually calculated as per Bill of material for the Item being produced. Consumption of material (fabric, thread, button, and twill tape) is calculated and estimated as per cost of each material.

Loading production: Planner defines (as per Orders) which style to be loaded to the production line and how much quantity to be loaded.

Process selection & planning: Processes needed to complete an order vary from style to style. According to the order (customer) requirement PPC department selects processes for the orders. Sometimes extra processes are eliminated to reduce the cost of production.

Facility location: Where a company has multiple factories (facilities) for production, factories are set for a specific product, planner needs to identify which facility will be most suitable for specific orders. Sometimes there may be a capacity shortage in a factory, in that case, planner need to decide which facility will be suitable for new orders.

Estimating quantity and costs of production: Planner estimate daily production (units) according to the style's work content. With estimated production figure, production runs and manpower involvement, planner also estimate production cost per pieces.

Capacity planning: PPC department plays a major role during order booking. It decides (suggests) how much order should accepted according to available production capacity. It allocates total capacity or decide how much capacity to be used for an order out of total factory capacity. It regularly updates factory's current capacity (production capacity).

Line planning: Preparing detailed line planning with daily production target for the production line. Most cases line planning is made after discussion with the production team and Industrial engineers.

Follow up and execution: Whatever plan is made is executed by PPC department. PPC department keeps close look whether everything is progressing according the plan. It chases other department heads on a daily basis to keep the plan execution on track. It updates order wise completed tasks on the Time & action sheet. When it finds something is going to be late they expedite and create an alarm about the delay.


Maker Making

The maker making is one of the most important tasks in the garment manufacturing industry. Accurate maker making helps to reduce fabric, material wastage which ultimately reduces the cost of making finished garments.

Fabric Spreading

To cut the fabric properly, fabric is spread in the play form. Fabric spreading is done manually or by using the computerized method.


In this stage, the fabric is layered on a table, layer by layer up to a certain level. Then by means of cutting machine, fabric are cut into garment shapes or pattern and separated from the layer. This cutting can be done by manually operated blade cutting machines or by computerized laser beam cutting.

Sewing /Stitching

Garments are sewn in an assembly line with the garment becoming complete as it progresses down the sewing line. Sewing machines operators receive a bundle of cut fabric and repeatedly sew the same portion of the garment, and passing that completed portion to the next operator in line.

For example, the first operator may sew the collar to the body of the garment and the next operator may sew a sleeve to the body. Quality assurance is performed at the end of the stitching line to ensure that the garment has been properly assembled.

Thread Trimming

After stitching, all hanging threads are cut by means of hand trimmer. Auto thread trimming machines are also available to perform this task. All loose threads inside the garment are removed as well. Garments without any loose thread and long tail is the very basic requirement.


This process is performed when the buyer wants washing or special finishes to the garments. generally, for light colour, garment washing is carried out to remove dirt and stains.

Finishing & Ironing

After sewing, we get a complete garment which is treated with steam ironing and several finishing processes are done including extra loose thread cutting.

Additional Processes

To make the garment more attractive / or as per requirement few additional processes are done like dyeing, printing, embroidery for the value addition.

Packing & Folding

Each pressed garment is then folded with tissue or cardboard. Folding varies from product to product and also from buyer to buyer.

Hang tags, special tag and price tag are attached with plastic Kindle or thread. Folded and tagged garments are then packed into the poly bags / desired packing.

Final Inspection

Generally, this process includes checking of the garment, measurements checking. After completion of all process, all pieces are checked by quality check team to ensure that garments are being made as per buyer's quality standards. Checking is normally done for visual appearance and measurement.


After completing all the process, the garment is now ready for dispatch.

SERVUNTO™ - ERP On Device assists manufacturing houses to carry out multiple processes with ease, particularly when number of simultaneous Buyer Orders increase and when it becomes increasingly difficult in managing the complexity. Few of the functions available in SERVUNTO™ are as follows: -
Merchandizing | Buyer Order Management Procurement | Inventory Management
  • Track Product Life cycle from sampling to order delivery
  • Create Costings, Budgets, BOM sheets
  • Track Product Development
  • Do Post Shipment Costing and profitability analysis
  • Create Purchase orders for material purchase as well as job work
  • Track Inventory, Track purchases and deliveries
  • Perform Vendor rating, smart allocation of purchase orders
  • Optimise inventory allocation across Orders ensuring lower costs.
Production Planning Production | Execution
  • Smart Production Phase Allocation tool.
  • Visual based Production planning
  • Easy movement of Material amongst Production Phases
  • Get Planned Vs. Actual Costs
  • Track production -Material Issue to Receipt in Finished Goods Warehouse
  • Perform Quality and production analysis
  • Track Outsourced and in-house Production
  • Perform Planned Vs. Actual production
Financial Accounting Shipping
  • All standard accounting reports such as P&L, B&S, Trial Balance etc
  • Approvals, Linked with purchase and production to ensure bills are linked with actual operations
  • Perform variance and profitability analysis
  • Multi-Curreny. Generate statutory reports in excel, CSV
  • Invoice and Packing List formats
  • Track pre and post shipment documents
  • Back to Back LC, Insurance and Freight tracking
  • Perform Planned Vs. Actual production costs

Modules are configurable to match company's manufacturing processes and security requirements. For details click Servunto Features

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