Production Process
Production is at the base of every finished good so it goes without saying that investing in a well-defined, structured production process will be key to any physical product's success. Below we give a general outline of the production process for an average pair of denim jeans, but product specifications and client instructions will ultimately determine the exact steps followed and their order.
Pre-production
The pre-production process begins with the arrival of the raw materials to the plant. For jeans the typical materials received are fabrics, rivets, buttons, zippers, and threads.
Once the material has been unloaded, it is stored in the corresponding “bin” in the inbound storage area. We have bins for each component which contain sub-bins for separating each component by lot. The inbound storage area operates under a traffic light system; material labeled green is material that has been fully inspected and found fit for use, yellow is material that has yet to be inspected and red is material that has been found unfit for use.
Using the rolls of fabric as an example, each roll is placed one by one onto a roller where we check for both physical damage and stains. A built in UV light helps check for stains not visible to the naked eye, once the integrity of the roll has been checked it’s stored in the adequate bin. If the client needs the cutting pattern of the fabric calculated on site, then this is calculated using CutWorks and if not, cutting begins.
Cutting
The material is then brought to the cutting table where a line drawing machine is used to trace the cutting pattern onto the fabric and then it is cut.
When a roll of fabric has been consumed, all the same sized pieces are grouped together and checked to make sure they have been cut correctly.
Each piece once verified is then stamped in a non-visible location to trace the batch throughout the production process for continuity.
Some pieces such as the back pockets may be ironed before the sewing process begins. After completing the checks, stamping and ironing of the fabric (if required) we go to the sewing tables.
Sewing
The sewing process is the most variable process in making a pair of jeans so let’s just look at the addition of the back pockets having already mentioned them.
The back pockets are loaded into the sewing machine, the machine lowers one back pocket at a time onto the corresponding leg piece and the machine sews them together using the pre-programmed design. Other important sewing steps include the attachment of the front pockets, the combination of the leg pieces, the attachment of belt loops and the sewing of zippers. All these processes use distinct machines. Due to the high level of variability in the sewing stage, our CAPA (Corrective and Preventative Action) team works with our Quality team to keep all workers up to date on the possible errors each machine can produce and how to avoid and/or rectify them should the need arise.
Finishing
Once the jeans are dry the finish is applied based on the jean and the client’s instructions. If any small stitches such as the bottom hem remain, they are completed here. Then the jeans are brought to the spraying and brushing booths. First, the jeans are placed over a pair of tubes which are inflated to fill out the jeans. Then any loose threads remaining are brushed away and finally, the jeans are sprayed to give them the desired color. Once the jeans have been brushed and sprayed, they are brought to a different area where the rivets, buttons, and final embroidery designs are attached. The jeans are then ironed a final time and the labels are sewn on. Once the jeans have been fully assembled, they are inspected and then packed according to the client´s packing list and stored by lot/size in the outbound storage area, ready to be shipped to their destination.
Washing
This is where the magic happens, all the fabric pieces have been stitched together to form the shape of the jean and it’s time to bring it to life. Each jean has a specific wash or set of washes associated with it, these can vary in duration, the chemicals used, and the number of washing/drying cycles. At our plant, we predominantly use stone washes. The jeans are loaded into the washers with pumice stones, the washer is then closed, and the security lock engaged. The operator then selects the desired parameters of the wash and initiates it. Once the wash is complete the jeans are separated from the stones and dried via tumbling. We have many industry-grade washers and dryers to carry out this process.
Quality Control
We utilize WIP(Work-In-Process) software and paperwork to monitor both the maintenance and production of the plant. The regular calibration and recalibration of the machinery used in the plant are critical in providing a safe environment for our employees and ensuring product quality. At each step in the production process, the integrity of each garment is checked by a verifier, and then both the operator and verifier sign off on its quality. If a production error occurs, it is evaluated on how it can be avoided in future, and then each operator is briefed on how to avoid or troubleshoot it in future. These are just some of the ways we ensure the highest quality control for the highest quality products.
