Feb 14, 2023

Apparel Design: Optimizing Production Plan Thorough Tech Pack Review

Preventing Apparel Production Losses through Thorough Tech Pack Review


In the field of apparel design and tech pack development, minor mistakes can lead to significant losses. If instructions are provided accurately in the garment spec sheet, the outcome would be correct, and time and money expenses would align with the garment's costing and delivery timeline. However, if mistakes in the tech pack are overlooked during the review process, problems can escalate to significant monetary losses during sample development and production. Small oversights can result in a considerable expense, making it crucial to review tech packs thoroughly and ensure that all specifications in the spec sheet are correct. Tech pack review is essential, and tech pack designers should give their best effort to ensure accuracy.





Avoid Costly Mistakes: Accurate Tech Pack Review


A tech pack contains vital information and instructions that factories follow without question. It serves as a contract, and factories abide by it entirely, except when given new instructions during sample development. It is not recommended to alter a tech pack once it has been handed over to the factory, except for significant issues related to production feasibility or impossible jobs given in the tech pack instructions. When developing a sample, the details specified in the tech pack guide the development of trims, prints, embroidery, tags, labels, and other items. This process involves preparing the final prototype, developing dies, print screens, embroidery CADs, and other significant components required for a garment sample. It is a costly process, and the factory invests a lot of money in the development of these items.

Changing these dies, CAD, and other components can result in double the cost, which can be avoided by conducting a thorough tech pack review. It is the responsibility of both the brand owner or line sheet designer and the tech pack designer to concentrate and focus on reviewing the tech pack to ensure it is perfect to the optimum level before it is handed over to the factory.

I can provide an example based on my experience during the garment development and production process. One of my clients made a minor change to their website address, and a single letter needed to be added, but it was overlooked. It may seem insignificant on the surface, but in practice, it was a significant issue during sample development, and rectifying the mistake was a costly process. Similarly, even a small mistake in the garment fit measurement could result in the garment shape being entirely different, and sometimes the entire shipment of the garment gets rejected. Therefore, it is crucial to review the Tech Packs as many times as possible before they reach the apparel production unit.

Essential Tech Pack Audit for Clothing Brands


A Tech Pack Audit is essential and unavoidable for a new clothing brand that has limited resources to establish its garment label and succeed in the market. New line sheet designers with less experience should seek out well-equipped and experienced Technical Designers or reputable design studios. Technical Designers often provide information that is unnecessary for garment units, which can be confusing and result in the wrong product being produced. Therefore, only the necessary information should be provided in a clear and concise manner so that garment units can comfortably develop the product. Changes to the tech pack can be made easily and at a lower cost, but producing garments with the wrong specifications cannot be reversed and can result in significant losses for the apparel brand.

Step-by-Step Apparel Production Planning


When conducting apparel production planning and scheduling, it is essential to take a step-by-step approach for two reasons. Firstly, it saves time and, as a result, reduces the cost of production. Secondly, it increases the quality of the garments, thereby significantly reducing the rejection rate. The properties of raw materials have a direct impact on the final product of the production order. However, it's important to consider the human factor, which is equally significant and cannot be overlooked. Garment pre-production activities are planned and executed by people, not computer programs, yet the critical path method (CPM) often ignores this factor. The apparel production process is complex, and some processes cannot be executed by a computer and cannot be fitted into CPM. Specifically, pre-production activities such as tech pack designs, sample development, garment pattern design, print, and embroidery designs require a human touch.