Apparel production errors can lead to wasted materials (costing money), slow production output, and unhappy customers. These errors can surely hurt your firm, but you can get production quality right and ensure things run smoothly. But what are the most common mistakes made in apparel production, and how do you rectify these errors to get better results?Â
Maker’s Row connects businesses to manufacturers that focus on quality control, reducing typical production mistakes. The platform assists in finding all the right partners who are experts in fabric cutting, consistent stitching, and correct sizing, which results in fewer hiccups to deal with. It simplifies communication and is beneficial for both parties in contributing to better collaboration and ultimately higher-quality apparel production.
Production Errors and Brand Image
Frequently occurring production errors, such as stitches coming undone, zippers breaking or becoming stuck, fabric stretching with very little use, and clothing that appears ill-fitting, are all indicators of a company with poor quality control processes and an inefficient team. If customers keep noticing the production errors, then they will develop a negative image of the company, and this will in turn result in negative PR amongst their social circle. A company might lose their preexisting customers and also potential customers who might have thought that the products were appealing but after hearing the review changed their mind. It is pertinent to always ensure that you put your best foot forward to please your loyal customers and also maintain the reputation of your brand.
Here are some common production errors and the solutions to them:
1. Incorrect Pattern CuttingÂ
An incorrect size or an off-putting pattern are a result of fabrics that were unevenly cut. This is what occurs when dimensions are off, fabric quality is subpar, and various other mistakes pile on.
Production Solution: Never use equipment that is of low grade; try using digital tools that help in aligning the fabric and the stitches, which in turn reduces human error. The best way to reduce even further errors is to conduct regular inspections and have frequent training sessions for employees.
2. Inconsistent Stitching
A lack of straight and even stitching can make an otherwise perfect garment look cheap, and it almost always leads to an uncomfortable wearing experience. It is typically a result of either bad machine maintenance, wrong tension, or inexperience in the maker.
Production Solution: Sewing machines are equipment that need proper oiling and maintenance to perform well. Make sure all of your team members are trained to know the recommended tension changes and how fabric should be sewn. Inspect the garment, line up the sleeve with the edge, and closely and carefully observe the stitches so they are not faulty, as this will come undone later once it is too late.
3. Uneven ColouringÂ
Colour discrepancies are common in mass production, and they are a huge reason for customers to be unhappy. Dyeing imperfections are the most common reason for colour variations.
Production Solution: Dye all pieces from the same lot under strict controlled conditions. Use a colour-matching system such as spectrophotometers to test evenness. Inspect the colour consistency of incoming fabric before production starts.
4. Sizing InaccuraciesÂ
Garments that fit poorly = lots of returns and customers complaining. Inaccurate pattern grading (usually due to the challenges of sizing a pattern for mass production) results in improper fit points, and they are generally off by an inch or two. Clothes might show up on your company’s doorstep sometimes months after you expect it; they will look off, and it will be too late to get it rectified.
Production Solution: Follow standard size charts and make accurate pattern grading. Reduce the mistakes via automatic grading and test the fit and size of the garment on real models and mannequins in order to prevent this issue before it goes into full-scale production
5. Seam Slippage and Breakage
Garments can end up falling apart at the seams where they are weakest, like pockets and waistbands. Seam problems occur when the stitches are not reinforced or the wrong tension is applied during stitching.
Production Solution: Educate your employees to strengthen the seams in high-stress areas. Use more robust thread and set your machine tension slightly higher for slippery fabrics. Test garment strength often, and it’s best to find weak points early.
6. Fabric Defects
Problems in fabric like stains and tears can spoil perfectly-looking clothes instantly. These errors are commonly caused by bad fabric handling or issues with the suppliers.
Production Solution: The inspection of the fabric shipment before going into production. Keep fabrics in a controlled storage space so they do not spoil before production starts. Inspecting the fabrics on a regular basis will eliminate problems later on in the process.
7. Misaligned Prints or Embellishments
Misaligned patches, logos, or embroidery look odd and ruin the entire product image. Such mistakes occur when prints or materials are not well aligned upon application.
Production Solution: Use the right templates or guides so that aligning becomes easy. Along with this, automated printing or embroidery machines can be used. An inspection each time the embellishments or prints are applied should be done to see whether the application is proper before resuming production.
8. Loose Buttons or Zippers
Buttons, zippers, or fasteners that are poorly attached may make garments essentially unwearable. This is usually due to stitching that is too weak or improperly attached to the fabric.
Production Solution: Train employees on the proper attachment of buttons and zippers and use quality materials. Machine adherence to get the appropriate attachment methods may also help in lessening the possibility of human error. Regular inspection for all needs should continue throughout production.Â
9. Poor Packaging
A poorly made package might lead to the delivery of damaged garments to consumers or leave a bad taste with customers before opening the parcel. A lot of times, improperly packed, wrinkled, or damaged products become a bad look on the company.
Production Solution: Implement proper folding, tagging, and protection standards for each garment. Packaging that is both environmentally sustainable and performs the vital role of protecting products in transit should be used. Instructing the packaging team, combined with regular verification checks, can provide for a quick fix of any possible errors that may occur before dispatch.
10. Breakdown in Communication
Poor communication between the design team, production staff, and suppliers can lead to using the wrong fabrics by the team; picking unfit fabrics with lots of alterations will be time-consuming compared to selecting the perfect pattern-fitting style, which will cause fewer issues during production such as delays in timing, late delivery, or quality problems.
Production Solution: Every department should establish clear lines of communication. You need a unified system for the dissemination of design specs and production standards. Regular team meetings are necessary; they should be held to keep everyone informed, and that reduces the likelihood.
Maker’s Row for Reliable Manufacturers
If you are a brand or factory from India, China, Bangladesh, Vietnam, or Turkey, just starting out or already in the industry, it can be hard to find good manufacturers, but this platform makes the process easy. Maker’s Row pairs businesses with carefully prescreened U.S.-based manufacturers to minimise problems such as defective pattern cutting, uneven stitching, or flawed sizes. It makes it super easy to find the right manufacturers for your specific needs—low minimum order quantities, sustainability practices, and garment types. If you are trying to find a reliable manufacturer, then Maker’s Row is the way to go.
Conclusion
Production errors are inevitable when it comes to apparel manufacturing, but that does not mean they have the ability to destroy your business. Being able to identify problems like incorrect pattern cutting, stitching issues, and inaccurate sizing is beneficial in ensuring a better level of quality with your garments, along with reducing costly mistakes. In addition to regular upkeep of equipment and training employees properly, the secret is doing rigorous quality checks at each stage during production.
Read More…
