Garment manufacturing requires systematic execution of technical processes to ensure quality and efficiency. As an ISO-certified manufacturer handling 500+ monthly productions, Ludyway implements standardized workflows across all projects – from small-batch custom hoodie manufacturing to 10,000-unit orders. This guide details industry-optimized procedures.
1. Market Analysis and Forecasting
Conduct quantitative research before production:
- Analyze historical sales data for similar products
- Determine optimal order quantities using ABC analysis
- Establish reorder thresholds based on lead times
Ludyway’s planning team reduces overstock risk by 35% through predictive analytics integration.
2. Technical Design Development
Transform concepts into production-ready specifications:
- Create dimensionally accurate CAD flats
- Specify seam allowances (±1.5mm tolerance)
- Define hardware placement coordinates
3. Precision Pattern Engineering
- Develop master blocks using ASTM D5585 standards
- Implement grade rules: 4cm between sizes for bust/hip
- Digitally nest patterns to minimize fabric waste
4. Cutting Marker Optimization
Automated marker making considerations:
| Fabric Type | Efficiency Target | Yield Improvement |
|---|---|---|
| Woven | 82-85% | 7-9% vs manual |
| Knit | 78-80% | 5-7% vs manual |
5. Fabric Cutting Protocols
Ludyway’s cutting department implements:
- Laser cutting for synthetic fabrics
- Band knives for dense natural fibers
- Die cutting for uniform manufacturing consistency
Maximum stack height: 100 layers (cotton) / 60 layers (stretch knits)
6. Bundle Management System
Efficient workflow organization:
- Color-coded ticket system for size segregation
- Kanban-controlled work-in-progress flow
- 15-minute changeover between styles
7. Thread and Trim Selection
Technical specifications for t-shirt manufacturing:
- Thread: Tex 40-50 for construction
- Elastic: 160-180% recovery rate
- Interfacing: Weight-matched to base fabric
8. Machine Configuration
Equipment calibration standards:
- Needle size: #11-14 (based on GSM)
- Stitch density: 12-14 SPI for seams
- Tension: 200-250g pull test
9. Assembly Line Production
Specialized workstation setup:
- Single-piece flow for premium items
- Modular system for bulk private label manufacturing
- SMV-based balancing (≤5% variance)
10. Quality Assurance Process
Four-stage inspection protocol:
- In-process checks (critical operations)
- Pre-assembly panel verification
- Final assembly AQL 2.5 audit
- Pre-shipment dimensional validation
11. Finishing and Packaging
Garment-specific treatments:
- Steam pressing at 120-140°C
- Anti-microbial finishing for sports apparel
- ECO-friendly polybags (15μ thickness)
12. Logistics Coordination
Global distribution management:
- Barcode tracking system
- Consolidation hub optimization
- Customs clearance documentation
Post-Production Analysis
Ludyway implements closed-loop improvement:
- Collect retailer sell-through data
- Analyze production efficiency metrics
- Implement PDCA cycle for continuous enhancement
Our vertical integration reduces lead times by 30% compared to industry averages. Request our manufacturing playbook for optimized production planning.
