Sweater Manufacturing Procedure

Sweater Manufacturing and Merchandising Procedure

Production Flow Chart of a Sweater:

  • Yarn Received from Textile
  • Yarn inspection (Random Method)
  • Winding Section
  • Yarn Cone Distribution to the Knitting Operator
  • Knitting Section
  • Knitted Panel Inspection
  • Linking Section
  • Linking Inspection
  • Linking Continue / Trimming Section
  • Inspection by Cylinder Type Light
  • Mending Section
  • Washing section
  • Hydro Extracting
  • Drying
  • Pressing
  • Finishing
  • Labeling (Main, Size, Care etc.)
  • Button Hole, Button Attach, Zipper (If required)
  • Price Tag & Hang tag attach
  • Folding
  • Primary Packaging
  • Quality Audit by Quality Control Team
  • Final Inspection
  • Final Package & Ready to Export

List of Machine required for a Sweater Factory:

  • Winding M/C
  • Knitting M/C
  • Linking M/C
  • Washing M/C
  • Hydro extractor M/C
  • Dryer M/C
  • Boiler M/C
  • Steam Iron
  • Over Lock M/C
  • Label Sewing M/C

Common yarn used in the Sweater Manufacturing Basic Type:

  • 100% Acrylic
  • Acrylic Melange
  • Blended Acrylic
  • 100% Wool
  • Mixed Wool
  • 100% Cotton
  • Blended Cotton

Fancy Type:

  • Chenille
  • Angora tweed
  • Nep yarn/ Slub yarn
  • Mohaire
  • Tape yarn
  • Kashmere like

Types of Stitch/Design Used in Sweater Manufacturing:

Basic Type:

  •  Jersey
  • Rib
  • Double Jersey

Fancy Type:

  • Shaker/Half Cardigan
  • Full Cardigan
  • Milano
  • Drop Knit
  • Pointal
  • Diamond (Normal Diamond, Fancy Diamond)
  • Zigzag
  • Tuck
  • Cable (Normal Cable, Fancy Cable, Butterfly Cable)

Sweater Style

Sweater Style depends on following factors:

Body Shape

  • Fitted Waist
  • Straight Bottom for Unisex
  • A-Line Shape for Ladies only

Shoulder/Armhole Shape

  • Straight Shoulder
  • Raglan Shoulder
  • Saddle Shoulder
  • Set-in Shoulder
  • Drop Shoulder

Neck/Collar Shape

  • Mock Neck
  • Crew Neck/Round Neck
  • V-neck
  • Polo Shirt
  • Sailor Neck
  • High Neck
  • Boat Neck
  • China Neck/Collar (Band Collar)
  • Turtle Neck
  • V-Insert
  • Round Neck with Rolled Edge

Sleeve Shape

  • Sleeve less
  • Cap Sleeve
  • Short Sleeve
  • 3/4 Sleeve
  • Long / Full Sleeve

Pocket

  • Plain Pocket
  • Hexagon Pocket
  • Round Pocket
  • Square Pocket
  • Hidden Pocket
  • Below Pocket
  • Real Flap Pocket
  • Fake Flap Pocket
  • Fake Up Pocket
  • Wetted Pocket
  • Inverted Pocket
  • Box Pocket

Consumption Calculation of Sweater:

Basically sweater is made from yarn not from fabric. Sweater consumption is calculated based on the weight of sweater or the requirement of yarn to make a sweater. Say, yarn required for 12 pcs sweater= 18 Ibs, Wastage=8% Then, sweater consumption= 18 + 8% = 18+1.44 = 19.44 Ibs/dzn

Costing Calculation of Sweater

Costing of a sweater depends on the following factors:

Types of Season:

Peak Season

Off-peak Season

Types of Gauge Used in Sweater Machine

Course Gauge/ Normal Gauge (3G, 5G, 7G)

Fine Gauge (10G, 12G)

Type of Gauge Depends on Season

Type of Gauge: 3G, 5G, 7G 10G, 12G

Off-peak Season: September-February March-August

Peak Season: March-August September-February

Cost of Manufacture (CM) per Dozen

Type of Gauge: 3G, 5G, 7G, 10G & 12G

Off-peak Season: $17/doz, $18/doz, $19/doz, $22/doz

Peak Season: $19/doz, $2o/doz, $21/doz, $24/doz

Wastage of Yarn is as Follows:

  • Wastage Type of Gauge & Yarn             Wastage- %9
  • Course Gauge + Good Yarn                    Wastage- 8%
  • Fine Gauge + Good Yarn                         Wastage- 8%
  • Course Gauge + Chenille Yarn               Wastage- %8
  • Fine Gauge + Chenille Yarn                     Wastage- %10

Styling Charge

  • Raglan and Saddle Shoulder = $ 0.50/dzn
  • Set-in and Drop Shoulder = $ 0.25/dzn

Designing Charge

  • Diamond (Normal)= $ 1.00/dzn
  • Diamond (fancy) = $ 1.50/dzn
  • Cable (Normal) = $ 0.25/dzn
  • Cable (Fancy) = $ 0.50/dzn
  • Cable (Butterfly) = $ 1.00/dzn

All of the above charges may change from time to time.

Suppose, buyer has given an order of Men’s Pullover with crew neck, Raglan shoulder Long Sleeve. Design: 4 lines Normal Diamond, 4 lines Fancy Cables. Machine Gauge=3G, Price of Yarn=$2.00/lbs (100% Acrylic Yarn), Yarn Requirement=18 lbs/dzn, Shipment Date is 30 June,2013. Make a costing for 12 pcs sweater (FOB).

Solution:

Yarn Consumption=DYarn Requirement +Wastage=18+6%=18+1.08=19.08 Ibs/dzn Yarn Cost= Yarn Requirement X Yarn Price= 19.08X2.00=$38.16/dzn CM= $ 19.00/dzn Styling Charge= $0.50 (for raglan shoulder) Designing Charge= (4X1+4X0.50) = $6.00/dzn (4 lines normal diamond,4 lines fancy cables) Trims & Accessories= $ 4.00/dzn Profit= 20% of CM=$3.8/dzn Sub-total= $71.46/dzn Commercial Cost (3%)= 2.14 Sub-total=$73.60/dzn %3D Buying Commission (5%)=$3.68/dzn,Total FOB Cost= $77.28/dzn ($6.44/ piece)

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