Trouser Manufacturing Process – How the Production is Done
Have you ever wonder how the trousers are made? You see readymade trousers in shops, you wear trousers. Did you ever saw how these trousers are made in factories? What are the processes used by manufacturers to make a trouser?
As a trouser manufacturer I will tell you details behind the clothing production and more specifiacally trousers production.
The process of trouser manufacturing when done by a full-package manufacturer involved the following processes.
They follow these steps to manufacture trousers (listed in the sequence of occurrence) –
- Pre-production processes, designing the patterns
- Selection of fabric and trims as per the buyer specification
- Procurement of fabric, trims, and accessories
- Storage of fabric and trims in warehouse
- Quality checking of fabric and trims
- Pattern development, samples production, grading trousers patterns
- Fabric spreading, lagging the fabric and cutting
- Ticketing and bundling of cut components
- Trouser stitching process
- Quality checking of stitched trousers
- Washing if needed
- Ironing process
- Quality checking
- Folding and Packaging
- Final Inspection and quality audit
- Delivery of shipment
1. Pre-Production Process
Before starting any order, there’s a design to talk through. We need to talk through what a client want to get as a final product. We can ask for photos, sketches, professional designs, technical sheets.
When we have the design, we then go for fabric and trimmings pick for the production. We are developing trouser sample and send them for approval. We have to establich size set, possible make the size set samples. As a specialists in trousers manufacturering we can start the production very fast. When the client approved the samples, we can start bulk cutting and the whole production.
Pre-production meetings can be made through emails, telephone, zoom meeting, other digital and online meetings, whatsapp, whatever is best for both parties. After the samples are done and approved, the production planning are done.
2. Selection of fabrics, trims as per the buyer
Depending on the product detailing and product specification, factory can select suitable fabrics or source fabrics on the clients demand or accept the fabrics that the client will send to our headquarters. We have large portfolio of fabric mills that we work with, from polyester, mixed fabrics, to more luxury wool, linen, cotton fabrics. We can advise and source the fabric for the client, this all depends on what the clients want and how much work we agree to to for the client. We also work on private label, meaning we can sell our own products on our established patterns and fabrics.
Wheather it will be casual trousers, men classic pants or women trousers, there are different trimming need to be ordered for the production.
In a formal trouser, you need trims like- buttons, sewing thread, waistband courtain, knee linings, pocket linings, zipper, metal hardweare like hooks, labels.
3. Procurement of fabric, trims, and accessories
Depending on what basis we work with the client our factory prepares a bill of material according to the material consumption and order volume or we source materials and details needed for our account. The sourcing team will source fabrics and trims for the production.
4. Storage of fabric and trims in warehouse
After the procurement of raw material, all raw materials are to be kept in a proper place that is in a storage-area/warehouse with ambient temperature, humidity required for the fabrics, and other raw materials.
5. Quality checking of fabric and trims
The fabric inspection is done by laying it on the inspection table against the light. Fabric inspection and approval of fabric are done before cutting process so that unevenness in colour/shade or any other faults if any visible in the fabric are eliminated. The same level of checking is to be followed for trims and accessories.
If needed the fabric grouping is done, we need to prepare different fabric lots. Cutting of different shades, but same fabric is done in same layers, different layer of fabric are made, when we work with different fabrics.
For fabric approval, for some orders fabric sample is sent to a testing lab for verifying physical and chemical properties of the fabric. Fabric must pass the quality checking and lab testing.
6. Pattern making and grading
Simultaneously after the approval of the order, pattern master is assigned to make patterns that will go for further marker planning and cutting department for production. Trouser patterns can be made manually or by using a CAD system. After pattern making, grading of the patterns is done for all sizes.
7. Marker planning and cutting
A marker is commonly done by large thin paper that holds all the size of pattern pieces for a specific style of garments. Marker is the perfect way to reduce fabric wastage. The marker gives actual guidelines for completing the flawless or correct fabric cutting. Marker making can be done in both ways like manually and computerized methods.
8. Fabric Spreading & Cutting
Spreading is a preparatory operation for cutting. The main aim of the spreading process is to lay the several fabric plies essential for the production process to the marker length without any tension on the fabric. The lay height depends on order size, fabric characteristic, capacity of the spreader, cutting method and equipment used. The preference of a mode of spreading will influence the cost of spreading as well as finished garment quality. For small orders we do the spreading mostly manually using the straight knife cutting machine or made to order, the bigger orders and bulk orders are made by automatic cutting machine
9. Ticketing and bundling of cut components
Whenever the bundling system is used, it is accompanied by tickets or bundle tickets. It gives fundamental information about the work such as the style number, the size of the garment, the number of garments in the bundle, and the date issued.
After cutting the entire fabric lay, all the garments components in stack form is shorted out as per size and color. To avoid mistakes in sorting, it is better to use code number on each pattern.
10. Trouser stitching process
The next process is the stitching of trousers using sewing machines. Cutting bundles are moved to the sewing floor and loaded to sewing lines as per the loading plan. In a line, sewing machines of different types are arranged as a vertical line to assemble the garments. The sequence of types of sewing machine arrangement depends on the sequence of assembling operations. The number of sewing machine arrangements per line may be different depending on the design and output quantity of trousers.
Normally, a trouser line is set up in sections – preparatory sections, front section, back section, and assembly sections. We have qualified team of seamstresses that are experts in each trouser detail, so the whole production sections work together as one team, but every person is doing his part. In the preparatory section small parts are made and the move to the assembly section. Once front part and back part of the trouser is ready, sewing operators assemble the trouser.
11. Quality checking of stitched garments
Inline quality checking – Inside the sewing lines, quality checkpoints are kept. Normally, after making each trouser part, stitching quality is checked by a trained quality checker.
All garments are thoroughly and carefully checked to detect/find any defect is present in the garment. The defects may be for example variation of measurement, sewing defect, fabric defects, spots, etc. if the defect is possible to overcome, then the garment is sent to the respective person for correction.
End-of-line quality checking – After the garment assembly, an end-of-line checker checks the whole trouser inside and outside. Check cut the loose and uncut thread tail if found any. She also removes ply number tickets from the trouser.
If the checker found any stitching defect, missing of any operations, defective trousers are given to the operators who made the defect of missed an operation. After correcting the operation, the end-of-line checker recheck the pieces and passed them for the next process.
12. Washing of trousers
Washing is an important process in cotton trouser manufacturing and chinos. For cleaning and adding softness to the trouser. Washing is done using mild detergent. Industrial washing machines are used for trouser washing. After washing, the garments are hydro extracted to remove excess water and after this, these garments are dried in tumbler dryer.
13. Finishing process (pressing and ironing trousers)
In the finishing stage, thread trimming is done. 100 percent of the trousers are checked by the quality checkers. If stains are found on the fabric, stains are removed using spotting workstations. Then individual trousers are pressed by steam presses on a vacuum table to remove wrinkle marks. Here we also can make the crease on trousers using steam vacuum machine or turn-ups in trousers if needed. Pressman follows pressing instruction.
After pressing, visual inspection is done one more time and random measurement checking is done the same checker. Now trousers are ready for folding and packing.
14. Folding and Packing of trousers
After the final inspection, the trousers are put on hangers and put into plastic bag, that is if we do tailored trousers. For cotton chinos we can fold them and put into cartons. Hand tags are attached. As per packing requirement pieces are poly packed. Then trousers are sorted by color-wise, size ratio wise, bundled and packed in the cartoon.
The cartons are marked with important information in printed form which is seen from outside the cartoon easily. The trouser manufacturing process end after packing the trousers.
15. Shipment for delivery:
Finally, the packed cartons containing formal trousers are shipped to the buyer’s address.
As you see the process of manufacturing trousers are very long, detailed and needs to be done by professionals. We are making formal trousers for 30 years now, we have made experts of ourselves and our team.
If you have any questions and want to know more or use our team to develop your collection drop us an email.