– Bulk color not match the sample
– Bulk shrinkage is unstable, spec is not fit
– Washing takes so long delay the shipment
I believe most of denim buyer or production manager have meet above mentioned production issue, almost every one will see it. How can less the issue?
A piece of jean looks simple, but it is much complex from fabric to a finished products. Many buyer doesn’t know the production process but have to face that why my bulk order feels completely off? Sample looks good, but bulk has various kinds of color shade. And the spec is off and leading customer return, Why? Lets breakdown the above most common issue in denim
Normally when making sample, it usually wash separately in small washing machine by a master craftsman while units are less than 10pcs. But in bulk run, it is in a standard machine which usually over 100pcs for one lot. This requires a high level of skill from workers to control the chemical and the use of the pigment, but also the sensitive to the temperature.
In addition, the manual whisker, PP spray, broken holes for bulk are done by ordinary workers, the control of the tools and chemical liquid from each person is different, which results in variations between each piece.
The lack of quantifiable wash standards, poor the washing control experience from workers, and the factory’s overconfidence etc will enlarge the issue.
-One piece bulk sample sign-off to sure the different within the acceptable range
-Checking the first lot color if possible and requiring the shade lot
-Working with washing mill with rich experience and quality control system-
-Selected the right supplier who have standard control of the quality
The approved sample fit perfectly, but after first washing, it become ripe up or tighten. Even in same pattern but measurement is different. It is most troublesome problem for all denim manufacturers. In fact, sample is sewed in sample room by single person, but in bulk productions, it involves different workers sewing different part, it is one of results inconsistent. In addition, nowadays modern denim fabric contain spandex for comfort wearable feel. However, the spandex will shrink after washing. To know the fabric shrinkage is most important in the denim production. So doing the shrinkage test of bulk fabric is a must in the beginning. Not only one roll of the fabric, need test more to get the average since the cutting pattern is one set.
-Choose the quality fabric not only the color, but also with the stable shrinkage
-Test the average shrinkage of bulk fabric before cutting
-Checking the spec before washing
-One piece bulk sample to do home washing test if have time
A promised 45days lead time delay to 60days , that miss the sale season. And the rushing production leads to quality issue, like thread ends, smelly or risk of mold. You must understand the denim whole process and sure the approved sample is ready when starting counting the lead time. Most factory lead time 30~45days is base on sample approved and fabric is stock. When approving sample process is delay, that will effected the delivery. Moreover, denim need washing, the hand-sanding, scraping etc need manual. The sales seasons are close, so brands shipping periods will be with a specific time, so that will be a line which need to considering.
-Full timeline planning, make sure to have some more extra buffer time for the washing
-Understanding the the factory’s schedule, make sure sample approved on time
-Sure bulk fabric arrives on time
-Plan the shipment in advance according to the sales season
Denim is not a simple products you need to know it more and understand its characteristic, so that can avoid the problem as much as possible. The problem mentioned above is frequently happen and cause the looses easily. There are many other issue may also arise. What is the biggest denim production issue or mistake you have met? Leave your message,let’s talk about and figure it out.
Reego Denim focus in jean move than over 20 years. Start from a small workshop, now deeply working with many fashion brand with creative design and high quality production, annul capacity reach 2million pieces. Reego has three subsidiary factories, all of them have BSCI/QIMA certification, not only producing denim jeans, casual pant, denim jacket but also expanded the products to sportswear recently.
Moreover, Reego has strong design team and will launches new series every season to keep up the fashion trends. And the R&D department and collaborate with denim fabric supplier like Advance denim, AI denim, Hotline Textile etc to develop new cost-effective denim fabric.
In Reego practice, it is not only sewing. We need to select the most suitable fabric and test the shrinkage, try the washing color to ensure the sample meet the requirement. We also do final inspection of sample details before sending, to sure the sample you get is perfect.
Moreover,we always strive to lower the waste through the whole production process , as part of of our commitment to sustainable production. To support the new brand, we offer flexible trial order solution to meet their small batch needs.
In Reego practice, communication is essential. Before staring, our design and pattern master will review all the technical details and discuss any difficult point, that will help minus the potential errors and ensure the fit, color, styling is wanted and this jean is manufacturable.
02Feb
07Feb
by
Comments are closed