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FPQM Mid-Term
FPQM Mid-Term
Building on the The Pattern Fit is King Testing, Time Bridging the
Prototype Master's Role Testing... Management is Gap
Key
Proto sample Factory experts create Garment fit is crucial Fit sample is assessed 45-day target for fit One-month buffer
approved! the initial fit pattern. for sample on a live model or sample submission between proto
Fit sample uses actual Adjustments are development success. dress form. (after proto approval). approval and fit
measurements for a made based on 2-3 samples are Bulk fabric needs sample submission.
more precise fit. desired fit. created to ensure time for delivery (20-
optimal fit. 25 days).
Buyer may nominate
fabric supplier or
provide it directly.
Development of fabric sample
1. Fabric Selection:
1. Criteria include color, fiber content, texture, hand feel, and physical/chemical
properties.
2. Factory explores market or collaborates with suppliers for required fabric.
2. Fabric Development:
1. Garment maker provides fabric quality requirements to suppliers.
2. Negotiation of fabric price and development of lab dip and desk loom.
3. Testing fabric samples to ensure desired quality before bulk order.
3. Bulk Fabric Approval:
1. Fabric swatch sent to buyer for approval.
2. Bulk fabric sourced from pre-approved suppliers based on consumption
calculations.
4. Fabric Quality Inspection:
1. Fabric checked for faults and defects using systems like the 4-Point System.
2. Tests include GSM, shrinkage, and color bleeding.
3. Pre-shrinking and pattern modifications may be necessary based on test results.
Development of fabric
sample
5. Fabric Sorting and Shade Banding:
• Fabrics processed in different lots leading to shade variations.
• Shade bands prepared to ensure consistency in garment color.
6. Sourcing for Trims and Accessories:
• Trims and accessories purchased in advance of production start.
• Consumption per garment calculated to determine requirements.
7. Quality Checking of Trims and Accessories:
1. Inspection and approval of trim quality before production.
2. Testing for color bleeding in trims like laces, tapes, buttons, zippers,
and draw cords.
3. Defective items separated to ensure only quality trims are used in
garments.
Fit Sample and Salesman Sample Development
Process
Garment
Size Set Sample Size Set Sample GPT Approval
Performance Test Timely Execution:
Objective: Importance: Process:
(GPT):
• Evaluate garment fit • Crucial stage for • Mandatory for • Buyer doesn't ask for • GPT conducted
across multiple sizes ensuring correct fit clearing buyer's GPT sample simultaneously with
(e.g., S, L, XXL). before bulk requirements. submission; requires Size Set sample to
• Number of samples production. • GPT sample sent to test report. avoid delays.
determined by • Corrections made to third-party • Test results must be • Ensures timely
buyer's requirements. pattern grading if inspection or in- approved by buyer submission of PP
• Pattern grading needed. house testing lab. well in advance of sample and Planned
checked for • Actual fabric used; • Tests defined by PP (Pre-Production) Cut Date adherence.
accuracy. similar quality may buyer's protocol. meeting.
be used if actual
fabric unavailable.
Pre-Production Sample
Approval Process
1. PP Sample Preparation:
1. Made in actual production line or sampling department.
2. Crafted with actual fabric, trims, and accessories.
3. Typically, 3-4 PP samples made for one style.
2. Purpose of PP Sample:
1. Allows operators to understand what they will produce.
2. Ensures adherence to style specifications.
3. PP Sample Distribution:
1. Samples sent to buyer for cross-checking detailing and workmanship.
2. Typically, one sample for buyer, one for vendor, and others for internal use.
4. Buyer Evaluation:
1. Buyer reviews sample for compliance with style specifications.
2. Approves PP sample if everything is as per requirement.
3. Variations may prompt re-submission or comments for correction in bulk production.
Pre-Production Meeting and
its importance
Purpose:
• Align all stakeholders involved in garment production.
• Reduce chances of mistakes in bulk production.
• Clear any misconceptions about the product and address issues.
Benefits:
• Ensures everyone understands the production process.
• Facilitates building strong relationships between buyer agents
and factory personnel.
• Group discussion aids in improving production processes.
Methods of Pre-Production Meeting
Key Considerations:
• Several factors must be considered during the pilot run process:
• Processed in the production line, not the sampling section.
• Includes all sizes and colors in the pilot quantity, possibly using jump sizes instead of
all sizes.
• Quality of pilot run pieces may be checked by buyer QA if requested.
• Pilot run pieces are included in the bulk quantity for finishing and shipment.
• Generally, not conducted for small orders.
Conclusion
• Effective pre-production management is the cornerstone of success in the
apparel industry. By investing in meticulous planning, sample development, and
quality control measures, manufacturers can optimize resources, ensure timely
delivery, and meet market demands. Embracing innovation, sustainability, and
ethical practices is crucial for navigating industry complexities and achieving
sustained growth. In conclusion, mastering the pre-production process is
essential for apparel businesses to thrive in today's competitive landscape and
build enduring partnerships with buyers and consumers.
THANK YOU