Most Production Problems Begin Before Production

 

Most Production Problems Begin Before Production

Many people believe that production problems start on the sewing floor.

They blame operators, sewing quality, or factory management.

Sometimes that is true.

However, after more than 40 years in the garment industry, I have learned that most production problems do not begin in production.

The real problems often start during development.

Unstable patterns, insufficient testing, construction methods that are difficult to sew consistently, and poor communication between departments.

These issues may not be visible during sample development, but they almost always appear once production begins.

Production does not create most problems.

It simply reveals them.

That is why I believe the key to successful apparel manufacturing is not fixing problems faster, but preventing them before they happen.

In my experience, prevention is always less expensive than correction.

The companies that survive in the future will not be those that produce the cheapest garments.

They will be the companies that achieve the best balance of quality, cost, and reliability.

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