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Technology has transformed the apparel manufacturing industry in recent years. from design to production to distribution, and it has scientific art involving fashion techniques and designing. Constant technological advancement has brought many changes in the field of garment industries, resulting in increased efficiency and quality. The apparel industry continues to be at the forefront of design technology, pushing the boundaries of innovation and creativity to create products that are both fashionable and functional. In this blog, we will examine the role of technology in the apparel manufacturing industry and how it has benefited the industry.

Current Technology in Use

Design

Hand-drawn sketches and physical prototypes are becoming increasingly rare. Clothing designers can now easily create intricate and complex designs thanks to the introduction of computer-aided design (CAD) software. Adobe Illustrator, CLO 3D, and Optitex have made it possible to create 3D prototypes that can be shared with manufacturers and clients for feedback and approval. This not only speeds up the design process, but also guarantees greater accuracy and precision.

Digital Printing

Digital printing technology has revolutionized the apparel industry by allowing designers to create intricate designs with precise detail. Digital printing can be used on a range of materials, including cotton, silk, and polyester, and is ideal for creating vibrant colors and patterns.

Laser Cutting

Laser cutting is a design technology that offers accuracy and efficiency in the production process. This technology uses a laser to cut fabric into precise shapes, which reduces waste and speeds up the manufacturing process. Laser cutting is ideal for creating intricate designs and patterns that would be difficult to achieve with traditional cutting methods.

Production

The apparel manufacturing process has also been changed by technological advancements. Much of the manual labor used to make clothing has been replaced by automated machines and equipment. Computer-controlled blades, for example, are used in automated cutting machines to cut fabric more precisely and efficiently than manual cutting methods. Sewing machines have advanced as well, with computer-controlled machines capable of sewing faster and more accurately than human workers. This has increased efficiency while also lowering the possibility of manufacturing errors. Here are some of the most important production technologies used in the apparel industry:

Computer-Integrated Manufacturing (CIM)

Computer-integrated manufacturing (CIM) is a production technology that integrates computer systems and software into the manufacturing process. This technology allows for more precise control over the production process, reducing the risk of errors and increasing efficiency.

Industrial Sewing Machines

Industrial sewing machines are a critical production technology in the apparel industry. These machines are designed to handle high volumes of fabric and can stitch continuously, allowing for faster production times and improved quality control.

RFID Technology

Radio-frequency identification (RFID) technology is used in the apparel industry for inventory management and tracking. RFID tags are attached to garments and can be scanned to track their location and monitor inventory levels. This technology allows for more accurate inventory management, reducing the risk of overstocking or stock outs.

Overall, these production technologies are essential in the apparel industry, enabling manufacturers to produce high-quality products efficiently and effectively. As technology continues to advance, we can expect to see even more innovative production technologies emerging in the apparel industry.

Quality Control

Because of technological advancements, manufacturers can now ensure that their products meet quality standards. Sensors and cameras can detect fabric and garment flaws, and computer algorithms can identify and sort out defective products. This not only improves the final product’s quality but also reduces waste and saves time. Quality control technology is an essential component of the apparel industry for producing high-quality products efficiently and achieving high customer satisfaction. As technology advances, we can anticipate the development of more sophisticated quality control technology to assist the apparel industry in maintaining a competitive edge.

Sustainability

Technology has played a significant role in making apparel production more environmentally friendly. The amount of water and chemicals required to produce printed fabrics has been reduced because of digital printing technologies. Air Dye and Color Zen are two cutting-edge dyeing technologies that use less water and energy than traditional dyeing techniques. Furthermore, as textile engineering advances, sustainable materials such as recycled polyester and organic cotton become more widely available.

The fashion industry is evolving into a more sustainable industry, owing to the adoption of innovative technology aimed at reducing the industry’s environmental impact. While it may be an ambitious goal, the adoption of sustainable technology is critical to ensuring a sustainable future for our planet.

Distribution

Finally, technological advancements have altered the distribution of clothing. E-commerce platforms such as Amazon and Alibaba have enabled manufacturers to reach a global market while reducing the need for physical stores and the associated costs. Furthermore, advances in logistics technology have enabled manufacturers to track their products throughout the supply chain to ensure that they arrive on time and in good condition. Technological advancements have had a significant impact on the apparel manufacturing industry. Technology has made the process faster, more efficient, more accurate, and more sustainable, from design to production to distribution. We can expect even more innovations that will benefit the industry as technology advances.

The Future Technology

The impact of technology on the apparel sector is not limited to design, production, quality control, sustainability, and distribution. There are several other areas where technology has had a significant impact. Here are a few more examples.

3D Printing

3D printing is a relatively new technology in the apparel industry, but it has already shown great promise. 3D printers can be used to create fashion accessories, jewelry, and even entire garments. This technology offers designers a new level of creative freedom, allowing them to create designs that are impossible with traditional manufacturing methods.
Many brands, both large and small, have been researching the possibilities for on demand production since the introduction of 3D printers. This will create new opportunities for customization, sustainability, and creativity in the apparel industry.

Overall, these design technologies are changing the face of the apparel industry, offering more creativity and efficiency to designers and manufacturers. As technology continues to evolve, it will be exciting to see what new possibilities emerge in the world of fashion and apparel

Personalization

With advances in technology, apparel manufacturers can now offer personalized products to customers. For example, companies like Nike and Adidas offer customized shoes that are designed specifically for each customer’s unique preferences and needs. This not only improves the customer experience but also helps manufacturers reduce waste by producing only what is needed.

Augmented Reality

Augmented reality (AR) is a design technology that has begun to make waves in the fashion industry. AR allows designers to create virtual clothing that can be tried on by customers using a smartphone or tablet. Customers can use augmented reality to create virtual clothing for avatars that mimic their body shape and movement. This technology has the potential to revolutionize the way we shop for clothes by allowing customers to see how garments will look before they make a purchase. Augmented reality (AR) technology has made it possible for customers to try on clothes virtually. Apps like Loom.ai and Dressing Room allow customers to create digital avatars of themselves and try on clothes in a virtual environment.

This not only makes the shopping experience more convenient but also reduces the need for physical stores.

Robotics

Some apparel manufacturing facilities use robotics technology to automate repetitive and dangerous tasks. Robots can transport materials, sew clothing, and perform quality control checks. This not only increases efficiency but also lowers the risk of worker injury.

Blockchain

Blockchain technology can provide end-to-end traceability, transparency in the supply chain and it’s used as record-keeping technology. This technology can be used to track supply chain processes, reduce waste and fraud, and provide information regarding product authenticity. This helps manufacturers identify and address issues like worker exploitation, environmental violations, and counterfeiting.

The combination and further development of these technology trends will likely transform Current methods of the apparel industry. As the focus shifts to improving product sustainability, supply chain efficiency, and enhancing of consumer experience.
In conclusion, technology has had a significant impact on the apparel industry, transforming virtually every aspect of the industry. As technology advances, we can anticipate even more innovations to improve the efficiency, sustainability, and transparency of apparel manufacturing.

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Denim has been a fashion staple for centuries, but its journey to become one of the most versatile and widely worn fabrics in the world is a long and fascinating one. From its origins as a rugged material for workwear, to its transformation into a symbol of youth culture and rebellion, denim has undergone many changes over the years. In this blog post, we will explore the evolution of denim, from its early days to the present, and look at some of the latest trends and innovations that are shaping its future.

Origins

Denim can be traced back to the 15th century in Italy, where it was known as “serge de Nîmes” (serge from Nîmes). This type of fabric was used to make sturdy work clothes, such as overalls and aprons, for workers in the textile mills of the city. However, it was not until the 1850s, when Levi Strauss and Jacob Davis created the first pair of denim jeans, that denim truly began to make its mark on the fashion world.

With their durable construction and comfortable fit, denim jeans quickly became popular with laborers, gold miners, and cowboys. Over time, the style and fit of jeans evolved to suit the needs of different groups of people. For instance, in the 1920s and 1930s, Hollywood began to incorporate denim in their movie and stars such as Marlon Brando and James Dean made it popular among the youth.

In the 1950s, denim truly became a symbol of youth culture, as a new generation of teens and young adults embraced the fabric as a form of rebellion against the more formal styles of their parents. Denim jeans became a staple in the wardrobes of teenagers and young adults, and the trend quickly spread to other countries, including Europe and Asia.

As denim grew more popular, designers and fashion brands began to experiment with new ways to incorporate the fabric into their collections. Over the years, we have seen the rise of denim jackets, skirts, dresses, and even accessories like bags and shoes.

Value adds

The process of washing denim has progressed significantly over the years. In the early days, denim was primarily worn as workwear and was not considered a fashionable clothing item. As such, the washing process was primarily focused on removing dirt and stains, rather than creating a specific look or aesthetic. The most common method used was to simply wash the denim in a washing machine using detergent and water.

In the 1970s and 1980s, as denim began to gain popularity as a fashion item, the washing process became more refined. One of the most common methods used at this time was stonewashing, which involved adding pumice stones to the washing machine along with the denim. The pumice stones would abrade the denim, creating a softer feel and a faded, worn-in look. However, this method was harmful for workers and was discarded for safety concerns.

In the 1990s, new washing techniques began to emerge, such as sandblasting. This method involved using compressed air to spray sand onto the denim, creating a similar worn-in look as stonewashing but with more intense abrasion. However, Sandblasting was also discarded due to severe health hazards for workers and severe environment damage caused by the sand.

In recent years, technology has allowed for the development of more advanced washing techniques. These techniques include laser technology, ozone technology, and others which help to create a variety of different looks and finishes, such as vintage, bleached, and distressed effects. They are also much more environmentally friendly, and safer for workers.

Today, there are several technologies used in washing denim, with a focus on sustainability and safety of workers. With advancements in technology and machinery, the denim washing process has become more advanced and efficient, while also being more environmentally friendly. It has also helped to improve the quality and appearance of denim, offering a wider range of styles and finishes to consumers.

The new trend

In recent years, denim has emerged: sustainable and eco-friendly production. Brands are beginning to use organic cotton, recycling and repurposing denim, and implementing closed-loop production.

Denim has also been at the forefront of innovation in terms of the technology and treatments applied to the fabric. From traditional stonewashing and sandblasting to newer methods like laser and ozone technologies, the finishes and looks of denim have evolved to new heights.

In conclusion, denim has come a long way since its origins as a sturdy workwear fabric. Today, it is a fashion staple that is worn and loved by people of all ages and backgrounds, and it shows no signs of slowing down. With the evolution of sustainable and eco-friendly production, and technology-driven treatments, we can expect denim to remain a staple in our wardrobe for years to come.

Market Size

As of 2021, the global denim market size was valued at around $85 billion, and it is projected to grow at a CAGR (compound annual growth rate) of around 4% during the forecast period of 2021-2028. The growth of the market is driven by factors such as increasing demand for denim products from various end-user industries, growing popularity of sustainable denim products and new technologies for denim production.

The rise in disposable income and changing consumer preferences are also among the factors that are driving the growth of the market. Additionally, the increasing popularity of denim products in emerging economies such as China, India, and Brazil is also expected to contribute to the growth of the market.

The rise of e-commerce and online sales platforms have also made it more convenient for consumers to purchase denim products, which is also expected to drive the growth of the market. The emergence of various new trends and styles in the market is also expected to attract more customers, which will further drive the growth of the market.

However, there are also factors that could limit the growth of the market. The high cost of raw materials and labor costs, along with the increase in trade tariffs and duties, are among the major challenges facing the denim industry. The impact of COVID-19 has also led to a slowdown in production and demand for denim products.

In conclusion, the global denim market is expected to grow in the forecast period due to increasing demand, technological advancements, and changing consumer preferences. However, rising raw material costs, trade tariffs and impacts of the COVID-19 pandemic are some of the factors that are expected to hamper the growth of the market.

All sorts of clothes, from sporting to office attire, from everyday wear to standout luxury pieces, are included in the garment market. Global demand for clothing and shoes is anticipated to increase once more in 2020, following challenges brought on by the coronavirus pandemic, which negatively impacted the apparel industry’s sales. In terms of revenue, the global apparel market is predicted to bring in about 1.5 trillion US dollars in 2021 and close to 2 trillion by 2026. The majority of this garment demand is being met by China and the United States, both of which are producing far more money than any other nation. The fact that the same two nations are significant participants in global trade may not come as a surprise. The nation having the largest export value of clothing is China. In terms of the value of apparel imports, the United States ranks second only to the European Union.

In ascending order, the top ten apparel retail markets in the world (by retail sales value in 2022)

China, USA, Germany, United Kingdom, Japan, India, France, Italy, Russia, Canada (Source Euromonitor)

In ascending order, apparel retail sales by region (in 2022)

Asia Pacific (39.3%), North America (23.3%), Western Europe(20.4%), Rest of the world
(16.9%).(Source Euromonitor)

According to industry estimates, the global apparel retail market will grow by 7.6-8.6 percent between 2021 and 2022. The annual growth rate, however, will slow to 4.0-5.7 percent in 2022-2024 and then to 3.8-4.6 percent in 2025-2026. Asia-Pacific, North America, and Western Europe will continue to be the world’s largest apparel consumption markets, accounting for more than 80% of retail sales. However, the Middle East and Africa, as well as Latin America, will be key emerging markets to monitor.

China and the United States will continue to be the world’s two largest apparel retail markets, with no immediate competitors. China and the United States are major players in international trade. China is the world’s largest clothing exporter, and the United States is the world’s second largest importer.

“Fashion is one of the world’s most important industries, driving a significant portion of the global economy. It is a key value-creating industry for the global economy. If the global fashion industry were ranked alongside individual countries’ GDP, it would be the world’s seventh-largest economy.” According to Euromonitor and McKinsey research reports published prior to the Covid-19 pandemic, the global revenue of the fashion industry was estimated to be between $1.7 trillion and $2.5 trillion.

Ethiopia Global Share in apparel industry

Ethiopia has long been regarded as one of Africa’s economic powerhouses. Until recently, it gained great political stability in comparison to other African countries. With an average GDP growth rate of 10% over the last decade and a government that implemented foreign investor-friendly policies, the country was able to attract South and East Asian clothing manufacturers. These are sold to international retailers such as Decathlon and H&M. Although Ethiopia’s textile and apparel sector is currently small its export share is less than 10% of all exports, and its output only accounts for 0.6% of the country’s GDP—it was predicted that over the following several years, the industry would expand by over 40% annually.

Despite these obstacles, the Ethiopian government’s efforts to make the nation a major sourcing hub and one of the most desirable destinations for global textile and apparel investments have not gone unnoticed. Heavy-hitting retailers like Gap, H&M, Tesco, Belk, and Walmart have factories in Ethiopia or obtain their clothing goods from there.

Global Apparel Market Drivers

Wireless Technology Advancement and the Growing Need for Connectivity

The growing popularity of online shopping is most likely driving the textile manufacturing industry. Manufacturers’ ability to sell their goods in a larger market than previously will widen their geographic customer base and fuel the growth of the textile manufacturing industry. E-commerce platforms, for example, have increased traditional clothing sales in countries such as India by increasing producers’ geographic exposure.

Increasing Clothing Demand from the Fashion Sector

The fashion business has a significant economic influence. Fashion firms are a multibillion-dollar industry. As a result, rising fashion clothes demand has a significant impact on the economy. It is responsible for both the recent and future expansion of the apparel industry.

Global Apparel Market Constraint

Coronavirus Pandemic

The outbreak of Coronavirus disease (COVID-19) has acted as a significant restraint on the textile manufacturing market in 2021, as supply chains have been disrupted due to trade restrictions and Consumption has decreased because of whole world government lockdowns

Growing Industrial Waste

The amount of waste in the manufacturing of apparel is very significant, which has led to an increase in both pre- and post-production waste. Many clothing cutouts and post-production garment wastes are dumped in landfills every day. If these things aren’t successfully handled, they have an impact on the environment.

The textile industry emits a lot of pollutants at every stage of fiber and fabric processing. Liquid discharge, solid waste, hazardous waste, air emissions, and noise pollution are examples of pollutants.

Textile waste is divided into two categories: pre-consumer waste and post-consumer waste. Pre-consumer waste is waste generated on factory floors during cutting and the manufacturing process of apparel making, which includes fabric selvedges and leftover fabric scraps. Postconsumer waste is created by items such as used clothing, towels, bedsheets, carpets, rugs, upholstery, and other textiles.

Waste minimization is the use of a systematic approach to reducing waste generation at the source. Waste minimization refers to the use of a systematic approach to reducing waste generation at the source. Hazardous and non-hazardous materials, water, energy, raw materials, all waste emissions, and other resources are all subject to waste minimization. It is not a one-time event, but rather an ongoing program. That is, it is a technique that can be applied to all process inputs and outputs.

In other words, waste minimization prevents waste from being generated in the first place, rather than treating it after it has been generated using end-of-pipe treatment methods.

Waste management in the textile industry is defined as the methods and actions required to manage waste from its beginnings to its final disposition. This includes waste collection, transportation, treatment, and disposal, as well as waste management process monitoring and control, waste-related laws, technologies, and economic systems. Economic barriers to waste minimization include insufficient funds or cash flow, poor communication, failure to prioritize waste management, and so on….

Types of Textile Waste

Spinning Waste
Weaving Waste
Knitting Waste
Dyeing Waste
Clothing Waste

Benefits of Waste Minimization

Implementing waste minimization has a number of advantages. These are some examples:

Environmental improvement
Reduces operating costs
Risk reduction as a result of improved understanding, control, and management of current and future risks and liabilities.
Improves process efficiency
Improves Employee moral
Protects health and environment
A competitive advantage gained by improving the company’s image

Waste reduction is accomplished through source reduction through process and product changes. Product modifications include (increasing product life, designing for less environmental impact.) Changes to the process include (improved operating practices, improved housekeeping, change in raw materials, and change in technology, in-house reuse or recycling)

Steps that can be taken to minimize textile wastage are as follows:

Reducing water consumption
Reducing chemical consumption
Energy Conservation
Reduce solid waste
Reduce the use of toxic materials
Optimum use of resources

Conclusions

The textile industry emits a wide range of pollutants at all stages of fiber and fabric processing. These include liquid waste, solid waste, hazardous waste, air emissions, and noise pollution. Energy consumption must also be considered because the fuel used to provide this energy contributes to the pollution load. It is critical to investigate all aspects of reducing textile industry waste and emissions, as this will not only result in improved environmental performance but also significant savings for individual companies.

In this era of globalized economies, the garment industry in especially required to provide lowest possible costs with fastest possible supply chains to survive. In this race, more often than not, factories tend to put their social responsibility or social compliance on the back burner.

Compliance means fulfilling/conforming to certain standards, rules, regulations, policies, SOP’s or goals set out by the organization. It can be:

National legal requirement
International legal requirement
Customer Requirement
Certification requirements
Internal Policies, procedures, guidelines

Social compliance is how a business treats its workers, and the environment it operates in. It is simply the minimal code of conduct that guides the business in regards to how its workers and environment should be treated, in regards to the employee wages, working hours, conditions, and environmental laws. Social compliance basically intends to protect both labor and environment interests.

Social accountability standards or social compliance have been developed by many international organizations like Fair Labor Association (FLA), Worldwide Responsible Apparel Production (WRAP), Ethical Trading Initiative (ETI), Business for Social Responsibility (BSDR), and Council on Economic Priorities Accreditation Agency (CEPAA). The guidelines from these organizations are widely being used by big brands to form their own social compliance standards.

The basic core areas that social compliance should include are policies on child labor, health and safety, forced labor, compensation, discrimination, working hours, discipline, management systems and right to free association and collective bargaining. In addition to these core areas, local culture and government regulations also become a part of social compliance in the industry.

Categories of Compliance

There are different types of compliance that are required from a garment unit to fulfill. Types of compliance with their brief introduction are as follows:

Social /Labor Compliance

This is the type of compliance where you are required to fulfill labor law requirements as required by National labor Law or ILO and some best practice requirements by customers. It covers:

Payment issues
Working Hours
Working Environment
Disciplinary practices
Labor Practices

OHS Compliance

In this type of compliance, you are asked to fulfill Occupation, health, and safety requirements. It can be Standards set out by local authorities or standards made by customers. Customers can also ask you to fulfill different international standards e.g. OSHAS etc. It covers:

Fire Safety
Machine Safety
Electrical Safety
Physical/biological Hazards

Environmental Compliance

Here a factory has to comply with Environmental requirements that can be local or international or requirements set out by the customer. Environmental Compliance covers:

How you manage waste of your facility?
You have environment permit or not?
What is the impact of your activities / processes?
How you manage your processes/activities to make it environment friendly

Product Quality Compliance

Product quality is a very important compliance area. This is where there is zero tolerance. If a product is not a quality product then you won’t get the customer. In Product quality compliance, we consider:

How a company manages its products?
How a quality product is ensured?
What are the faults?
How the defects are removed?
How material is handled?

Security Compliance

This compliance is mostly applicable to export oriented industries. This compliance arises due to terrorism and customer data protection issues. It will include:

Who have access to certain areas?
Who have access to data/files?
How products are packed?
How some areas are accesses restricted?
How site security is ensured?
How product design security is ensured?

Structural / Building Compliance

After the collapse of Rana Plaza in Bangladesh, international brands have now been trying to make sure that this does not happen again. Brands are conducting building assessments.

What is the strength of building?
What is the load capacity of the building?
What are defect in the building?
How building can be made safe?

Certification Compliances

There can be different types of certification e.g. Management system certification, social, environmental, quality, safety certification against different standards e.g ISO standards, BSCI, SMETA, etc. there might be some special requirements of these certifications depending on standards e.g. how documents are managed, etc.

Compliance Audit in the Apparel Industry

A compliance audit is one kind of audit that is specially designed for auditing the compliance issues related to the apparel industry. Different regulatory authorities set different types of regulatory issues. And buyers of garments ask from the company whether they are following their required compliance or not. These issues are checked by the auditing process which is known as compliance audit. After a compliance audit, they provide/ issue certificates. From the Compliance Audit Checklist in Apparel Industry a garments maker will be able to know what the things buyers may ask from the company are.

Licenses, Permits and Facility Information

Factory profile
Architectural & Structural Drawing Approval
Soil Test Report Approval
Trade license
Factory license
Fire license
Boiler license
Generator permission
Electrical permission/ Sub-station permission
TIN certificate
Export registration certificate and Import registration certificate
Export promotion bureau certificate
Bond license
Rent agreement

Child and under-aged worker

Child labor remediation process
Recruitment policy
Personal file
Agreement with the service provider/sub-contract

Forced labor and Discrimination

Any harassment or discrimination issues
Policy on a prohibition of forced labor
Awareness/Training register
The job responsibility of security guard

Freedom of Association and Collective Bargaining

Policy on freedom association
Awareness/Training register
Formation procedure of worker association/trade union
Meeting minutes of worker participatory committee
Register for complain /Suggestion
Grievance handling procedure

Right of Worker

Personal file of worker
Service book
Employee ID card

Disciplinary Practice

Policy on disciplinary practice or rules
Leave Record
Orientation training on factory code of conduct & legal requirement
All kind of policy
Disciplinary action log & record
Awareness/training register
Final settlement
Others legal facilities

Working Hours

Working hour Approval
Working hour record for all section
Overtime hour record
Attendance Register
Declared holiday list
Manpower list

Wages, Benefits & Compensation

Wages/payroll sheet (last 1 year)
Overtime wages sheet (last six months)
Pay slips (last 1 year)
Wages Increment record
Maternity Benefit register & Record
Group Insurance with manpower update list
Policy on wages, overtime, payment date, calculation method, leaves & holidays, etc.

Workplace Safety

Sub-soil/Geological investigation report
Building structural plan/approval
3rd party assessment report
Firefighting training record
Fire drill record
Firefighting team
Firefighting equipment list
Fire safety plan
Personal file of Fire Officer
Electrical & Mechanical Equipment periodical checklist
Competency certificate of Electrician
Competency certificate of Boiler Operator
Chemical Handling Training
Health checkup record
Chemical list
Safely machine operating training register
Needle stock register, Broken & Missing Register
Sharp tool policy
Emergency evacuation diagrams
Emergency exit doors
Building structure safety
PPE (personal protective equipment) use
Aisle or Stairway

Occupational Health & Welfare

Personal file of Welfare officer
Drinking water test report
First aid training & List of the first aider
Medical agreement
Competency certificate of Doctor
Competency certificate of Nurse
Personal file of care governance
Childcare register
Canteen committee

Environment Management

Environmental risk assessment as per section
Emergency procedure to reduce risk
Environmental clearance certificate
Waste disposal agreement /procedure
Wastewater test report in-house and outside
Energy survey/ Assessment record

Management Practice & Sub-contractor /Supplier Control

Awareness training record for new & old workers
Mid Management training record
Internal Audit record
Policy on Sub-contract control
Sub-contract control procedure & record

Training Records

Emergency evacuation & fire drill record
List of firefighters trained by fire service/BGMEA
Disciplinary Rules communication
First Aid training record
Chemical Training record
Machinery safety training record
Health and safety training record
Training on KIABI compliance

Company Policies

Child Labor Policy
Child labor Remediation Policy
Disciplinary Rules/Policy
CSR Policy
Anti-Corruption/Bribery policy
Sub-contractor/Supplier Monitoring
Grievance Procedure
Environmental Policy
Energy efficiency plan
Environment emergency procedure
Deduction for late/after lunch assentation

Lean manufacturing, also referred to as lean production, is a systematic approach to achieving highly efficient factory or plant operations by eliminating waste.

Apparel manufacturers try to produce quality products at reliable service. Lean tools help the apparel industry to identify and eliminate waste therefore there will increase profitability and productivity through all the processes, increase the quality level at the lowest cost rate, and these tools implement industry to focus on effective and efficient manufacturing processes for the Market. Productivity is directly proportional to the Time of manufacturing the product for this; the industry should eliminate all the wastes (Muda) and focus on a steady workflow.

Types of waste in apparel industry

The prime objective of lean management is to increase productivity and eliminate waste and non-value-adding operations from the production process. So it is essential to identify and eliminate this waste existing in the apparel industry. After implementing lean in manufacturing techniques industries achieve high quality at low cost and shorter lead time.

Transport: (moving products that are not actually required to perform the processing) when work is transferred from one place to another place, this process does not add any value to the product. So lean management identifies how to reduce transportation, where transportation can be eliminated, and where the transportation time can be reduced. Materials should be delivered to their location at a required time. Lean requires the materials to be transferred directly from the suppliers to the location in the assembly line where they will be used. This is called Point of Use Storage (POUS).

Inventory: (all components, work in process, and finished product not being processed) Inventories of a factory represent those items that are either in the process of manufacturing or ideal resources (material) of a factory or materials in stock. This waste can be minimized by starting a one-piece flow in the sewing department and reducing fabric inventory by proper utilization of fabric.

Motion: (people or equipment moving or walking more than is required to perform the processing) motion at workstations is found due to poor training of workers in working methods and habit of working in traditional ways. In industries where there are engineering departments to design workstation layouts, operators may use motion due to poor workstation layouts. Motion waste is minimized by reducing packing and folding time in the packing/finishing department, analyzing and eliminating high-risk areas, and locates at the fabric in the fabric store department by proper labeling and style.

Waiting: (waiting for the next production step, interruptions of production during shift change) this waste is defined as people or things waiting around for the next action. For example, Merchandisers wait for the buyer’s approval and supervisors wait for final instructions and go ahead for quality approvals. Waiting is a visible waste in the manufacturing department wherein operators and employees create nothing they just wait for work or due to other reasons. It comprises various reasons that are responsible to cause a delay in sourcing materials, cutting delays due to delay in fabric approval, and further consumption approval too. In the apparel industry waiting for waste can be overcome before bulk production is started in the fabric-cutting section.

Overproduction: (production ahead of demand) this waste can be simply defined as doing or making things that are not required now. Overproduction generates excess inventory. This waste generally occurs in cutting departments and sewing operations. Overproduction causes in balance in the work process. By setup up the visual link between the cutting department and production department, overproduction waste can be reduced.

Over Processing: (resulting from poor tool or product design creating activity) This is a waste of doing a task or adding features to the product that are not required from the customer. In the apparel industry, some operations may not be essential to give the final look and construction. Example: multiple checking in the finishing process. Lean techniques eliminate over processes, reduce panel inspection, and eliminate repacking and it can also be reduced by implementing a self-checking process.

Defects: (the effort involved in inspecting for and fixing defects) Producing defects while pattern making or another process there is a waste of money and effort. The lean management industry aims to produce garments for the first time. This is a dangerous waste among all the 7 types of waste because it causes other waste like re-transportation, reworking, and refinishing of that defective product. By proper fabric inspection and trim, inspection will reduce lead time in processing, by creating and analyzing proper fabric reports and using good quality fabrics and other materials.

Using lean tools, it is possible to achieve waste elimination and simultaneously map the current status of an industry. Some popular and important tools of lean are explained as follows:

Lean manufacturing principles

The approaches for implementing lean practices in the apparel, fashion and footwear industries vary, but the main principles of lean manufacturing are based on 5S and Kaizen.

5S is a workplace organization method comprised of five Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke. The 5S methodology describes how workspaces should be organized for efficiency and efficacy. Standardization of manufacturing items used how they should be stored, and how the items and area should be maintained help sustains the new order among workers and management alike.

5S can be translated as:

Sort: Eliminate that which is not needed.
Set: Organize what remains after sorting.
Shine: Clean and inspect the work area.
Standardize: Write standards for 5S.
Sustain: Consistently apply the 5S standards.

Kaizen is the Japanese word for “improvement.” In this case, it refers to the continuous improvement of all business and workforce functions at every level. In garment manufacturing, every level of production can be improved from raw materials handling to inventory.

Benefits of lean manufacturing

The benefits and advantages of lean manufacturing will be clearer to you after reading this below mention list:

Improve productivity and quality
Reducing Work in Process (WIP) inventory.
Eliminate waste and problems
Reducing inventory area
Reduce cycle and lead time
Production flow and controlled automation
Reduce manpower, time and space
Improve visual management
Reducing machine downtime
Optimize resources
Sustainability, employee satisfaction, and increase profit
Improve workplace and organize.
Improve safety conditions and housekeeping.
Increase customer satisfaction and customer service

Sampling is a process of making a product proto-type prior to starting bulk production. The same process is applied to garment sampling. In mass garment manufacturing, where apparel brands source garments in bulk quantity, sample making is an essential step before placing the bulk order. The prototype objective of the sampling is to eliminate the risk of making a wrong purchase of raw material or making a mistake in bulk manufacturing that is not accepted by the buyer. Sampling process covers garment fit checking, fabric and trims quality checking, approval value-added processes, and approval of complete finished garment. Most of the buyers have a standard requirement for garment sampling for the product for sourcing the bulk garment – what types of samples they need; when they need it; and how many pieces are needed for each sample type.

Sampling process involved many sub-processes including pattern making, pattern grading for different sizes, fabric development, processing of fabrics, raw material sourcing (choosing right fabrics and other trims), making garment including printing and embroidery processes (if required), sample checking and sample approval from buyers. During the sampling process, normally the buyer asks for changes if required multiple times as required to get the perfect sample. Suppliers need to re-submit the sample if the sample is not fulfilled the specifications and buyer’s requirement at the first submission.

Types of Garment Samples

Mock-up

The mock-up sample is the first rendition of a designer’s concept. Sometimes an idea does not translate as well on paper as it does on fabric, and this is where a mock-up comes in handy. It does not require any trimming and serves only to determine whether the garment is viable or not. Because not all designs necessitate a mock-up, not every designer or factory uses these types of samples.

Proto or development sample

The production cycle begins with the proto sample. Factories either follow the original sketch or a tech pack supplied by the designer. The idea is to only look at the style and design aesthetics, so it doesn’t have to be built according to the full specifications. Depending on availability, any fabric and trim of similar weight can be used. In most cases, three prototypes are created: two for the brand/reference designer’s and one for the factory’s reference.

Digital garment sample

A digital sample is 3D software rendering of the garment that allows the visualization of fit and fall in both stillness and movement. However, a complicated learning curve and high implementation costs may be the technology’s limiting factors. However, if brands can overcome this barrier, 3D printing can significantly reduce sample production costs and approval time between designers and factories.

Fit sample

Fit samples, as the name implies, are made to ensure the proper fit and fall of the garments and are made in accordance with the sizing requested by the brand. To pass the fit evaluation, measurements and construction must be accurate and correct. The fit sample can be made of the same fabric as the final design, and many adjustments may be required before the desired fit is achieved. At this point, you only need to include sample size specifications in your tech pack.

Size set sample

After the fit sample has been approved, the base pattern for each size must be graded so that samples for the entire size range can be created. Size set sampling includes three samples of each size made with the fabric and finishing’s that will be used in the final product. When the brand has given their approval to the factories, mass production can begin.

Salesman sample

As the name suggests, the salesman samples or SMS are the samples that are used for marketing and promotions of the product range. They are made with the final fabrics and final touches in the approved basic sizes. These are generally put on display in retail stores or exhibited at trade shows to get orders from respective retail channels.

GPT sample

GPT sample refers to the production sample that is given for “Garment Performance Test”. These samples are used for a series of tests that a brand would like to evaluate before running the styles for production. The tests can include seam strength, seam slippage, colorfastness, and wash fastness, among others.

Pre-production sample

A pre-production sample is the first sample made in the actual production line of the factory. It’s constructed with the actual fabrics intended for the design and trims with all the order specifications regarding measurements, embroidery, and washes. It’s a test run by the factory and they can proceed with the bulk production only when the PP sample is approved by the brand

Sealed sample

Once the PP sample is approved by the brand, they are sealed to prevent tampering from the factory and now become the standard for bulk production. They are also known as gold-seal samples or red-seal samples, depending on the approval, or disapproval of the brand.

TOP (Top of production) sample

After the approval of the PP sample, which signals the start of production, the Quality Control inspector representing a brand can visit the factory at any time and pick a garment from the production line for inspection. These samples are called “Top of production or TOP samples” and they are evaluated to ensure that the bulk production is of the same quality as the PP sample. TOP samples are also checked for their packaging.

Shipment sample

Once the bulk production is done and the shipment is finished, packed, and ready to go, a few samples are kept aside by the factory as shipment samples. These serve as to test the final product that will reach the brand; right from the folding to the packaging. Many brands will only approve shipping if the samples pass this test.

Press samples

Press samples are exact replicas of the final sellable product, usually in a model’s sample size. They’re used for photographing promotional material like collection campaigns for advertising, look books, e-commerce and can be loaned to magazines for editorial photo shoots.

The main purposes of the sampling process in the garment industry are given below:

To allow the buyer to judge the production capabilities of the manufacturer.
To provide a means for making revisions in the bulk production process.
To let the manufacturer estimate the thread and fabric consumption, and develop cost quotations.
To let the buyer know the potential of an exporter.
For understanding of the process flow, machine requirement, raw material consumption, risk analysis of making the new garment design (called as style),and product costing.

Every industry strives to be successful in its niche. However, success is only possible if three criteria are met:

Economic,
Social, and
Environmental

These criteria are assessed on a variety of grounds. These evaluations serve as the foundation for textile industry certifications.

Certification ensures that proper standards are met, expands customer reach, and assesses the quality management system.

Textile testing is one of the processes used to analyze various textile materials around the world in accordance with specifications. Textile testing assists businesses, consumer groups, and the government in ensuring that textile materials are safe, of high quality, and cost effective.

Standards are technical performance benchmarks and frameworks created by expert groups. There are both mandatory (legislatively required) and voluntary standards. Standards exist for every aspect of operations, and their effectiveness and reputation vary greatly.

Certification is a tool for companies to validate and communicate sustainability claims about their products. Certification occurs when an accredited independent body (an auditor) verifies that a supplier adheres to the appropriate standard. Upon successful verification, the auditor typically issues a certification statement.

Some of the widely popular certifications and standards in the textile industry are listed below:

International Organization for Standardization (ISO) 9001
Worldwide Responsible Apparel Production (WRAP)
Global Organic Textile Standard (GOTS)
Business Social Compliance Initiative (BSCI)
Fair Trade
ECO PASSPORT by OEKO-TEX
REACH
SA8000
Bluesign
Zero Discharge of Hazardous Chemicals (ZDHC)
Responsible Care
Registration, Evaluation, Authorization, and Restriction of Chemicals (REACH)
Green Seal
Leadership in Energy and Environmental Design (LEED)
Organic Content Standard (OCS)
GreenScreen
Fair Wear Foundation (FWF)
FLOCERT
Responsible Wool Standard (RWS)
Responsible Down Standard (RDS)
Recycled Claim Standard (RCS 100)
Sustainable Fiber Alliance (SFA)
Cradle to Cradle certification
Manufacturing Restricted Substance List (MRSL)

Standards and certifications that are widely used in the textile industry

1. International Organization for Standardization (ISO) 9001

ISO 9001 is applicable for companies, which are involved from designing to manufacturing of goods. This is the most comprehensive standard.

The organization which today is known as ISO began in 1926 as the International Federation of the National Standardizing Associations (ISA).

ISO is a voluntary organization whose members are recognized standard authorities, each one representing one country.

Each standard goes through a six stage process before being published as an ISO standard.

Principle of ISO:

Customer focus
Leadership
Involvement of people
Process approach
System approach to management
Continual improvement
Factual approach to decision making
Mutually beneficial supplier relationships

Advantages of ISO:

Well defined and documented procedures improve the consistency of output.
Quality is constantly measured
Procedures ensure corrective action is taken whenever defects occur.
Defect rates decrease
Defects are caught earlier and are corrected at a lower cost.
Defining procedures identifies current practices that are obsolete or inefficient.
Documented procedures are easier for new employees to follow.
Organizations retain or increase market share, increasing sales or revenues

2. Worldwide Responsible Apparel Production (WRAP)

WRAP (Worldwide responsible accredited production) is an objective, non-profit team of global social compliance experts dedicated to promoting safe, lawful, humane and ethical manufacturing around the world through certification and education.

Headquartered in Arlington, Virginia, USA (and with branch offices in Hong Kong and Bangladesh, along with a representative in India and Thailand).

Principle of WRAP:

Compliance with laws and workplace regulations
Prohibition of forced labor
Prohibition of child labor
Prohibition of harassment or abuse
Compensation and benefits
Hours of work
Prohibition of discrimination
Health and safety
Freedom of association and collective bargaining
Environment
Customs compliance
Security

Advantages of WRAP:

The WRAP certification program is grounded in the belief that factory based certification is the most effective way to ensure that work place comply with the WRAP Production Principles.
The WRAP program places primary responsibility for improving work place conditions on those who own and operate sewn product manufacturing facilities.
WRAP Certification Offers Market Advantage.
Acceptance of WRAP Certificate by multiple brands and Retailers eliminates duplication of monitoring efforts.

3. Global Organic Textile Standard (GOTS)

Advantages of GOTS:

The entire organic supply chain is covered, from harvesting to manufacturing and trading, delivering credible assurance to end consumers.
Verification through independent third-party certification.
Risk management tool for buyers.
Protection of health, safety, and rights of employees Social criteria and ethical business behavior are essential prerequisites that assure responsible business practices, irrespective of the organic orders at hand.
Cost-effectiveness through sustainability Certified Entities can use the GOTS Monitor (Water/Energy).
Only low-impact GOTS-approved chemical inputs free from hazardous substances are allowed to be used for the processing of GOTS goods.
Accessories are scanned for residues of hazardous substances.
GOTS goods meet technical quality parameters like colorfastness, shrinkage, etc.

GOTS certification is available for a wide range of products, including garments, home textiles, mattresses, combined products, personal hygiene products feminine hygiene, and food contact textiles.

5. Business Social Compliance Initiative (BSCI)

The Business Social Compliance Initiative (BSCI) is a non-profit organization. It was set up as an initiative of the Foreign Trade Association in response to the debate on how to achieve convergence in the field of corporate social responsibility. It implements the principles of international labor standards such as International Labor Organization (ILO) conventions, the United Nations Guiding Principles on Business and Human Rights (UNGPs), and guidelines for the Organization for Economic Co-operation and Development (OECD).

Advantages of BSCI:

Open up new marketing possibilities and strengthen the trust of customers, consumers, and business partners and employees.
Lay the foundation for future business relationships and thereby gain advantages in tender procedures.
Show a sense of responsibility for fair and safe production and working conditions.
Save costs and time by avoiding multiple audits.
Provide proof of improved working conditions and overall social commitment.
Improve the management of the value chain.
Create the perfect basis for SA8000 certification.

Importance of Standards and Certification in Apparel Industry

Standards are important in international trade because incongruent standards can be barriers to trade, giving some organizations advantages in certain areas of the world.

Standards provide clear, identifiable references that are recognized internationally and encourage fair competition in free-market economies.

Standards facilitate trade through enhanced product quality and reliability, greater interoperability and compatibility, greater ease of maintenance, and reduced costs.

Certification ensures that proper standards are maintained, enhances customer reach, and estimates the quality management system. Textile testing is one of the processes that is used to analyze various textile materials around the globe according to requirements.

The Certification Program is grounded in the belief that factory-based certification is the most effective way to ensure that workplaces comply with the Certification Production Principles.

Those who own and operate sewing product manufacturing facilities bear the primary responsibility for improving workplace conditions under the certification program. Certification Offers a Market Advantage Acceptance of a certificate by multiple brands and retailers eliminates duplication of monitoring efforts.

You have probably worn a garment composed of a polyester-cotton blend at some point in your life. The rationale for this is that the properties of this material make it less expensive to utilize.

Poly cotton is a common fabric that is widely utilized in the tactical field. Its numerous exceptional characteristics make it an excellent material for tactical clothes.

Cotton vs. Polyester

Cotton: is a soft, fluffy staple fiber (fibers of different, varying lengths) that grows in a boll, or protective case, around the seeds of the cotton plants of the genus Gossypium and spun into a yarn then woven to create a soft, durable fabric.

Cotton is comfortable and breathable. It is hypoallergenic. All of these properties make cotton the natural fiber of choice for nonwoven hygiene products, from feminine pads to baby care and adult incontinence.

But cotton has an even greater array of attributes suitable for a variety of nonwoven applications. In the fiber world, the strength of cotton is considered moderate to above average. The strength (tenacity) of cotton is 3.0-5.0 grams/denier when dry. This fiber is unique in that its strength increases when wet to 3.3–6.0 grams/denier. Cotton has a natural moisture recovery rate of 8.5% under normal temperature and humidity conditions. It also features a heterogeneous length distribution.

Polyester: is a synthetic fiber derived from coal, air, water, and petroleum. “Long-chain polymers chemically consisting of at least 85% by weight of an ester, a dihydric alcohol, and a terephthalic acid” is how polyester is frequently defined. Polyesters are easily flammable at high temperatures. Due to its wrinkle-resistance capacity, it is widely spun with other natural fibers.

Polyester is hydrophobic. For this reason, polyester fabrics don’t absorb perspiration or other fluids, leaving the wearer with a moist, clammy feel. Polyester fibers typically have a low level of wicking. Relative to cotton, polyester is stronger, with a greater ability to stretch. Fiber strength can range from 2.5 grams/denier to 9.5 grams/denier.

Environmentally concerned purchasers frown on polyester use. Since it’s a man-made fiber derived from petroleum-based products, polyester is not considered sustainable, nor is it biodegradable.

Cotton and polyester are often mixed to create garments with qualities that neither material can accomplish on its own. A fabric made from a poly cotton blend combines the strengths of the two fibers.

Polycotton fabric is manufactured by combining the natural fiber cotton with the synthetic or manmade fiber, polyester.

History of poly cotton

The earliest recorded mentions of cotton date back roughly 7,000 years ago. It was available in most places around the world by the 16th Century.

Cotton use really took off with the dawning of the Industrial Revolution in the 1700s. In fact, the arrival of that era was ushered in by the invention of a machine to separate the seeds of the harvested cotton plant from the valuable fibers. Cotton went on to become the most well-known fabric in the apparel industry.

There was also polyester. It has a far more recent pedigree than cotton. Polyester was discovered by British chemists John Rex Whinfield and James Tennant Dickson during a period when synthetic fibers were becoming more popular economically. Terylene was the trade name for polyester, but it was also known as Dacron.

Why Poly Cotton?

Mixing polyester and cotton gives people the ‘best of both worlds’ in terms of features and benefits. Here are a few illustrations of why polycotton has become so popular.

Wrinkle resistant
Tear-resistant
Shrink resistant
Cost (affordability)
Comfortable
Breathable
Strong and Durable fabric
Easy to care for
lower maintenance
Keeps Dyes in Place
Softer Material
Can be washed more often.

Types of Poly Cotton

There are different types of poly-cotton blend proportion (combinations), and they have different properties.

50/50 Blend Yarn: is most popular in this industry because of a balance between breathability and durability.

2. CVC Yarn:(Chief Value of Cotton yarn) in a cotton polyester blended yarn, when the amount of cotton fiber is more than polyester fiber it is called CVC yarn. The ratio of cotton fiber is always above 50%.

Example: 30 s/1 Ne (65/35) CVC Yarn means it is a 30-count single-ply cotton-polyester blended yarn where the ratio of cotton fiber to polyester fiber is 65:35.

3. PC Yarn:the amount of polyester fiber is higher than cotton fiber. It is a cheaper poly-cotton made up for mainly polyester.

Example: 30 s/1 (60/40) Ne PC Yarn means it is a 30-count single-ply cotton-polyester blended yarn where the ratio of polyester fiber to cotton fiber is 60:40.

How is Poly Cotton Processed?

The fusing of the fibers can be done at either the fiber stage or at the yarn stage. Although it results in a slightly more expensive fabric, combining them at the fiber stage tends to give a more superior quality.

To produce a polycotton yarn, the fibers must be blended before they reach a ring frame machine as roving. This blending process can mainly be done in two ways.

A. Fiber Blending

The quantity of cotton and polyester bales are listed in the laydown in the blowroom utilizing bale management according to the proportion of cotton and polyester fibers in the yarn. Following this, the two fibers are sequentially run through a fiber pluckering machine (often a Uniflock (Rieter) or Blendomat (Trutzschler) machine) and a series of ever more sophisticated cleaning devices. At mixing devices, most commonly referred to as Unimix (Rieter) or Multimixer (Trutzschler) machines, fibers are blended uniformly.

Fiber blending is the name given to this form of mixing or blending. Card slivers that have undergone this form of mixing can be produced. After that, the spinning flow chart is repeated until the ring frame machine creates yarn that is a blend of PC and CVC.

B. Sliver Blending

Cotton and polyester fibers are handled separately in this procedure from the blowroom to the carding stage. Then, cotton and polyester are used to create the individual card slivers. The polyester carded slivers are next passed through a one-phase draw frame known as the pre-pass phase to maintain the best possible sliver hank in order to enable better mixing. The slivers are then combined in a breaker draw frame using the necessary blend ratio. Slivers are doubled, sketched, and blended to the necessary ratio in a draw frame. The traditional spinning procedure is then carried out on a ring frame machine to create PC or CVC yarn.

Numerous tests have revealed that silver blending performs marginally better than fiber blending. Compared to fiber blending, silver blending allows for more exact maintenance of the cotton to polyester ratio.

Uses of Poly Cotton

Poly cotton fabrics are used in all kinds of sectors because they are easy, reliable and cost effective.

The most common practical applications of polycotton in today’s world are:

Fashion clothing:make it the go-to fabric material for clothing manufacturers globally.
Uniforms:Poly cotton is possible for workers to wear clothing that is breathable and absorbs moisture in demanding work settings when they become hot and perspire a lot.
Household textiles:is a versatile fabric material used for a range of textile products in virtually all homes. Examples include bed linen (fitted sheets, pillowcases), curtains, tablecloths, and more.

Typically, sourcing is finding the most suitable supplier that provides the quality of goods or services at a price point that gives the business owner the profit margins they need. In most organizations, the process of sourcing products or services is the first step in the supply chain process. Sourcing involves finding a balance between the quality of products and raw materials required and affordability.

The apparel sector manufactures finished apparel and leathers such as men’s, women’s, children’s, and intimate apparel. Apparel production is one of today’s most in-demand industries.

The method of determining how and where to source manufactured items or components is known as sourcing.

Apparel sourcing involves crossing borders to discover the best markets for their products all around the world. Apparel brands and retailers are prioritizing sourcing in order to increase product awareness and maximize revenues.

In terms of income generation and job creation, the apparel industry is critical to a country’s economic development.

The basic goal of apparel sourcing is to have control over where and how its products are made. It also reports to the merchandising department and is responsible for the timely and reasonably priced delivery of the essential commodities.

Types of apparel sourcing

Local manufacturer: Apparel is produced locally, using local infrastructure.
Conventional manufacturing: Local fabric is exported to the countries that manufacture apparels.
International sourcing: Fabric is produced locally, but basic raw materials, such as yarn or fiber, are imported from another country.
Global sourcing: As part of a global sourcing strategy, fabrics are manufactured with parts sourced from abroad.
Off-shoring: To meet demand, raw material is exported first, such as yarn or fiber, and then fabric is reimported.
Global manufacturing: Fabric is manufactured in another country.

Importance of Sourcing

The apparel merchandiser will source components of the product domestically or globally.
A supplier is assessed on

Price and quality standards,
Delivery times,
Managing risk,
Reputation of the supplier,
Capability to complete the volume of the order, laws, transport, and various costs involved.

Apparel sourcing process

There are several ways to start the sourcing process. Some companies will look first to companies that have good reputations in their apparel industry and see how they use as suppliers. They also solicit referrals from others in the business. Check industry publications, industry trade organizations, and trade shows for sources.

Selecting a Supplier: It is important to remember that when you are choosing a vendor, you are choosing a business partner. This needs to be someone you can trust and someone you can rely on now and in the future.
Securing a Supplier: Managing your inventory effectively helps reduce your holding costs and tying up capital that could be used elsewhere in your business. Whether you choose continuous replenishment, just in time inventory, or on-demand delivery, all require the cooperation of reliable businesses and suppliers.
Supplier Delivery Models: In the continuous replenishment model, suppliers make deliveries off a predetermined schedule, often in short periods, based on a company’s inventory data and/or real-time demand. Under a just-in-time delivery model, companies receive supplies on an as-needed basis. In doing so, they reduce inventory levels and costs because just in time delivers only what is needed to increase efficiency and decrease excess waste.
Create a Contract: Once you have negotiated the terms, it is time to draw up a contract. Don’t skimp on an attorney. If you make a mistake or leave it up to the supplier, you may limit your recourse should anything go wrong.

Check points for apparel sourcing

The materials to be sourced are checked for the following criteria:

Samples: The materials intended for purchase are assessed by the samples received from the vendors. The samples should be accompanied with their specifications.
Certifications: Some vendors provide certification of product quality. It is intended to provide the buyer with assurance of the quality of goods shipped while eliminating the need for receiving inspection. The certification may include the following,

Documentation of flaws and their locations
Test reports
Date of testing and the laboratory details

3. Order Minimum: The decision to source a material from a particular vendor is based on the “order minimum,” which is nothing but the minimum or smallest quantity a vendor shall supply on a single purchase order. Import goods may require a longer lead time but often have low minimums when compared to domestic suppliers. Minimums also relate to availability, order processing, packaging, and shipping costs.

4. Mode of Packing: The mode of packing is also important when a material is sourced from the vendor. If, for example, a firm wishes to purchase woven fabrics, they will be supplied in full width on a cardboard tube. The buyer should source goods based on the mode of packing so that the goods are not damaged in transit.

5. Delivery and Payment Terms: The buyer should clearly define the mode of payment and the delivery conditions so that there is no misunderstanding between the vendor and the buyer.

6. Professional Credibility of the Vendors: A vendor’s reputation in the trade is often a strong factor in determining whether the materials can be sourced from him. The buyer may check with the vendor’s client list and inquire about the quality of service and timing of delivery.

Factors affecting apparel sourcing

Lead time: The merchandiser needs to decide the supplier of the fabric on the basis of the type of fabric, and time remains to complete the export order.
Logistics: When placing an order, the merchandiser must take into account the following factors: cost of logistics, infrastructure needed for logistics, and time needed for transportation.
Quality parameters: The ability of the workforce and the workers’ flexibility to work on various apparel are the main determining factors.
Trade policies and politics: Policies are one of the major contributors to the product’s cost. Trade politics, and thus the resulting trade policies, are one of the key determinants of the decisions relating to the choice of suppliers.
Sourcing costs: The sourcing cost depends upon the following factors: labor wages, manufacturing costs, logistics (transportation), and Incoterms negotiated (for international sourcing). The freight charges are increased when there is a delay in manufacturing.
Supply chain management: Lean retailing, advances in IT, and multi-channel sales are forcing buyers to look for ways to optimize sourcing aligned to their supply chain management strategies. The dynamics of strategic sourcing functions like supply chain optimization also factor into sourcing decisions.
Minimum Order Quantity (MOQ): Every supplier requires a certain MOQ to produce the apparel economically. If the apparel exporter places the order of raw material below the MOQ, then the cost will generally be higher.
Ordering specifications: An apparel exporter must give specifications to the supplier to get accurate raw materials.

Apparel sourcing in Ethiopia

Ethiopia is fast becoming a rising star for sourcing apparels. The country’s efforts to build its textile and apparel industry and offer competitive prices in the international market have attracted a growing number of new buyers in recent years. (Source: Just Style)

The transformation of a small, obsolete and uncompetitive apparel industry into a strong export industry may seem a madman’s dream to most people, but not to sector observers who in the past witnessed the steep rise of the apparel industry in countries like Bangladesh and Cambodia. Until recently, the Ethiopian Government and a couple of pioneering Turkish textile companies stood nearly alone, predicting that Ethiopia would become the next big apparel sourcing hub. However, 2015 was the year of Ethiopia’s take-off Ethiopia’s main export market for apparels is Europe (with around 60 percent of the total export).

Half of Ethiopian textile and apparel companies are SMEs of 500–1,000 workers who are able to handle small-run orders for European mid-segment fashion retailers. Sweden’s H&M was a sourcing pioneer in Ethiopia. (Source: Apparel Resources)

Conclusion

The growing usage of sourcing strategies has had a significant impact on how goods are created, produced, and delivered. By implementing these improvements, the industry becomes more effective at meeting consumer expectations within a specific cycle time and for a reasonable price. Lead time, pricing, and quality are factors that affect how to source raw materials for the apparel industry. These techniques are significantly impacted by international trade and tariff legislation. In addition to these criteria, sourcing decisions are based on the state of the domestic market, cost-benefit analysis, state of the global market, ties between the relevant nations, and political stability of the nation.

To remain competitive, apparel manufacturers aim to expand their operations in a variety of ways. Furthermore, producers must prioritize variables such as changeable styles, short product life cycles, uncertain market trends, and client impulse buying behaviors in order to remain competitive in the apparel sector segment.

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