The Growing Role of AI in the Garment Industry

 The garment industry has long been a key part of global commerce, but like many other sectors, it is being transformed by the rapid advancements in technology. Among these, Artificial Intelligence (AI) is playing an increasingly significant role. From design and production to retail and logistics, AI is revolutionizing how garments are created, manufactured, sold, and distributed. In this article, we’ll explore the different ways AI is impacting the garment industry.

1. AI in Fashion Design and Trend Forecasting

One of the most exciting developments in the garment industry is the application of AI in fashion design and trend forecasting. Traditionally, designers have relied on intuition, creativity, and market research to predict what styles will be popular. Now, AI is enhancing these processes by analyzing vast amounts of data from social media, fashion shows, sales data, and even street styles to predict future trends.

• Trend Forecasting: AI tools can analyze consumer preferences and predict upcoming trends by evaluating patterns in data from sources such as social media platforms, fashion blogs, and past sales reports. Companies like Google and IBM have launched AI-powered platforms that can provide insights into fashion trends, consumer behavior, and color preferences, helping brands make data-driven decisions.

• Design Assistance: AI is also being used to assist designers in creating innovative patterns and garments. For instance, AI-powered software can generate design ideas based on inputs such as fabric types, colors, and styles. AI tools can also automate the process of creating 3D garment prototypes, saving designers time and offering more creative flexibility.

2. AI in Production and Manufacturing

Manufacturing is a core part of the garment industry, and AI is helping make production more efficient and sustainable. From automating tasks to improving quality control, AI applications in garment manufacturing are reducing costs and waste while enhancing productivity.

• Automated Fabric Cutting: One of the most labor-intensive tasks in garment production is cutting fabric to the right shapes. AI-powered systems like Gerber Technology’s AccuMark use advanced algorithms to optimize fabric layout, minimizing waste and improving precision.

• Smart Manufacturing Systems: AI-driven robots and automated machines are being used to stitch, sew, and assemble garments with high speed and accuracy. For example, Softwear Automation has developed sewing robots that can perform tasks previously done by humans, reducing labor costs and improving consistency.

• Quality Control and Inspection: AI can be employed in quality control systems to detect defects and inconsistencies during the manufacturing process. Visual AI systems use computer vision to examine garments for defects such as stains, stitching errors, or color mismatches, ensuring products meet quality standards before they reach consumers.

3. Supply Chain Optimization with AI

Managing the supply chain effectively is a challenge for the garment industry due to the global nature of production and distribution. AI is helping companies streamline their operations, reduce costs, and improve inventory management.

• Demand Forecasting: AI is revolutionizing inventory and demand forecasting. By analyzing historical sales data, weather patterns, and even social media activity, AI can predict which styles and sizes will be in demand, allowing manufacturers to produce garments with greater precision and reduce overproduction.

• Warehouse Management: In warehouses, AI-powered robots and sorting systems can autonomously manage inventory, improving accuracy and speed. These robots help in picking and packing products faster than human workers, reducing errors and ensuring quicker deliveries.

• Logistics and Shipping: AI is also improving logistics by optimizing delivery routes and predicting potential delays. By analyzing factors such as traffic patterns and weather, AI systems can help garment companies minimize shipping costs and ensure timely deliveries.

4. Personalized Shopping Experiences

Artificial Intelligence is also transforming the way consumers shop for clothes. Personalized shopping experiences have become a major trend, as AI tailors recommendations to individual customers based on their preferences, browsing history, and previous purchases.

• AI-Powered Virtual Fitting Rooms: Retailers are increasingly adopting AI-powered virtual fitting rooms, allowing customers to try on clothes virtually using augmented reality (AR) and AI. These tools analyze the customer’s body shape and recommend clothes that would likely fit well and complement their style. This reduces the need for physical try-ons, improving the shopping experience while cutting down on returns.

• Personalized Recommendations: Online stores like Amazon and ASOS use AI to analyze customer behavior and recommend clothing based on previous interactions, size preferences, and purchasing history. AI-driven algorithms continually learn and adapt, providing customers with highly personalized suggestions.

5. Sustainability and Ethical Production

Sustainability is a growing concern in the garment industry, with increasing pressure on companies to minimize their environmental footprint. AI is playing a role in helping brands create more sustainable and ethical production processes.

• Sustainable Design: AI can assist designers in creating garments using sustainable materials, helping to minimize the environmental impact. AI algorithms can suggest alternative materials that are both eco-friendly and cost-effective, contributing to the shift toward sustainable fashion.

• Reducing Waste: AI is being used in the textile industry to reduce waste by improving fabric usage during production. AI-based systems can predict fabric consumption and optimize cutting patterns to minimize material wastage, which is a significant issue in the garment industry.

• Circular Economy Models: AI can also support the development of circular fashion models, where clothes are recycled, reused, or remanufactured. AI can help track the lifecycle of garments, encouraging companies to develop business models that focus on reusing and recycling materials.

6. Customer Service and Chatbots

AI is also improving customer service in the garment industry. Retailers are increasingly turning to AI-driven chatbots and customer service agents to assist shoppers and handle inquiries efficiently.

• AI Chatbots: Many online retailers now deploy AI-powered chatbots on their websites and apps to provide instant customer support. These chatbots can answer questions about sizing, availability, shipping, and even suggest clothing items based on customer preferences.

• Automated Returns Management: The garment industry, particularly in e-commerce, faces high return rates. AI can streamline the returns process by automating certain steps, analyzing reasons for returns, and offering solutions to reduce return rates in the future.

Conclusion

AI is undoubtedly reshaping the garment industry in many ways, offering efficiencies and innovations that were once thought impossible. From design to production, supply chain management to customer service, AI is enabling businesses to streamline their operations, enhance customer experiences, and build more sustainable practices. As AI technology continues to evolve, its impact on the garment industry will likely expand, leading to even more exciting opportunities for brands, manufacturers, and consumers alike.

Garments Pre-Production Activity Check List

 Pre-production process is planning that is done prior to the bulk garment production. That includes samples development and approvals, sourcing and testing raw materials, garment costing, pattern making and process planning. Efficient production can't be reached without the pre-production processes.

Pre-production check list:

How to Calculate Minute Cost of Sewing Line in Garments Industry?

Method for Calculating Cost Per Minute of Sewing Line in Garments Industry:

An industrial engineer can easily calculate cost per minute of sewing line in apparel industry by following the two different formulas. Those are in the below:

1. Cost per minute of sewing line,

2. Cost per minute of sewing line,

Now, two examples are enough to clear all the confusions from the above discussion.

Example for the formula number-01:

Suppose, in Nishat garments ltd. total salary of sewing line for one day is 10000taka, no. of manpower’s for 20 machines is 30 and line efficiency is 50%, then calculate cost per minute in 8 working hours of each sewing line for that garments.

Solution:

Here,

Total salary of sewing line for one day = 10000 taka,
Total no. of manpower’s = 30,
Total working hours = 8,
Line efficiency= 50% = 0.5

Now,

Cost per minute of sewing line,

= 1.39 taka

So, cost per minute for each sewing line of nishat garments is 1.39 taka.

Example for the formula number-02:

Suppose, in Abonty fashion ltd. actual salary per day of all the operators and helpers is 15000, total garments produced per day is 400, where standard allowed minutes (SAM) for the garments is 20. Then calculate cost per minute of each sewing line for that garments.

Solution:

Here,

Actual salary per day of all the operators and helpers = 15000,
Total no. of garments produced = 400,
Standard Allowed Minutes (SAM) for the garments = 20

Now,

Cost per minute of sewings line,

= 1.875 taka

So, Cost per minute of sewing line is 1.875 taka.

How to Calculate Line efficiency of Garment Production

Calculation Method for Line Efficiency of a Garment Production:

An industrial engineer has to confirm the following items before starting the calculation method for line efficiency of a garment production:

1. Production output from the line (Pcs),
2. Standard allowed minutes (SAM) for garments,
3. Total number of operators in the line,
4. Total working hours.

Now, by applying all the above items in the below formula, an industrial engineer can easily estimate the line efficiency of a garment production.

Line Efficiency (%),

Now, one example is enough to remove all the confusions from the above discussion.

Example:

In Zara Fashion Ltd. a garment production line produced 300pcs Sweet shirt garments in 45 Standard allowed minutes (SAM) by using 40 operators, where working hours was 8.

Now, estimate the lines efficiency for the mentioned garment production.

Solution:

Here,
Production output from the line- 300pcs
Standard allowed minutes (SAM) for Sweet shirt garments – 45
Total number of operators in the line – 40
Total working hours – 8hrs

Now, by using the following formula, industrial engineer can estimate easily the line’s efficiency of the mentioned garment production.

Line Efficiency (%),

= 70.3%

So, lines efficiency of the mentioned sweet shirt garments production stands at 70.3%

How to Calculate Machine Capacity in Garments Industry?

Machine (hr) Capacity:

Machine (hr) capacity of a garment factory is totally related with number of sewing lines, sewing machines and working hours per day. Its directly proportional to the multiple result of those i.e. number of sewing line, sewing machine and working hours per day.

Sewing machine capacity

Machine Capacity Calculation in Garments Industry:

For calculating machine (hr) capacity in garments industry, we have needed the following information:

1. Sewing line in that factory,
2. Machines in each sewing line,
3. Working hours per day.

Now, by using the below formula, we can easily calculate the machine (hr) capacity in apparel industry.

Machine capacity,

= No. of sewing line in that factory × No. of machines in each sewing line × Working hours per day

Example:

Suppose, Lanny Fashions Ltd. has 10 sewing lines where each sewing line has 20 machines and working hours per day for the factory is 8, then calculate the machine capacity for that factory.

Solution:

Here,

No. of sewing line in that factory= 10
No. of machines in each sewing line= 20
Working hours per day= 8

So,

Machine capacity,

= No. of sewing line in that factory × No. of machines in each sewing line × Working hours per day= 10 × 20 × 8
= 1600hrs.

So, Machine (hr) capacity for the above garments factory is 1600 hrs.

How to Calculate Production Capacity of a Garment Factory?

Introduction:

Production capacity estimation for a garment factory is an important issue in ready made garments sector. It plays an important role to the buyer for selecting right vendor for their orders. How much a garment factory can produce their items per day has estimated here. As its importance in garments manufacturing sector, today I will present here the production capacity estimation method for a garment factory.

Production Capacity:

Production capacity of a garment factory is totally related with machine (hr) capacity, line efficiency of that factory and standard allowed minute (SAM) of produced item. For achieving accurate production capacity of a garment factory, an industrial engineer should confirm accurate cutting room capacity, finishing room capacity and washing capacity also.

Production in garment factory

Production Capacity Calculation Method of a Garment Factory:

For calculating production capacity of a garment factory, an industrial engineer should confirm the below information:

1. Machine (hr) capacity per day,
2. Individual product’s standard allowed minute (SAM),
3. Line efficiency of garment factory or factory efficiency.

Now, by using the following formula, an industrial engineer can easily calculate production capacity of a garment factory.

Production capacity (Pcs),

Example:

Suppose, Noman Fashion Ltd. has 10 sewing lines, each sewing line has 20 machines. They have to produce basic knitted polo shirt items at 8hrs working day, (where machine-hr capacity is 1600hrs and line efficiency is 60%).

So, find out the production capacity of that factory.

Solution:

Here,

Machine (hr) capacity per day= 1600hrs,

Line efficiency of garment factory= 60%,

Standard allowed minute (SAM) for knitted polo shirt= 20

So,

Production capacity (Pcs),

= 2880pcs

So, garments production capacity of the above factory is 2880 pcs per day.

How to Increase Higher Productivity | Concepts of Production and Productivity in Garment Industry | Productivity in Apparel Manufacturing | Productivity Improvement in Apparel Industry

Productivity in Clothing or Apparel Sector:

Productivity is a frequently talked about phrase in any production oriented enterprise. It is totally related with the profit percentage of an apparel export order in apparel industry. Destiny of an organization eventually depends upon quality and productivity. Many people conceive of productivity as an entity separate from quality. Productivity actually always encompasses quality. There is actually no meaning of high productivity if the products or services produced are of second quality.

Sewing line in readymade apparel industry

It is also unwise rather harmful to view productivity as activities related to production department alone. Productivity relates to all activities in the enterprise. This chapter shows how low productivity brings in a chain of vicious cycle in the organization, the measures to be taken to boost productivity in totality and how systems and processes promote productivity.

Production Versus Productivity:

Production generally refers to activities that convert resources into product or services while productivity is related with how specially products or services are produced.

20 Factors to Improve Productivity in Apparel Sector:

The following measures should be adopted through the enterprise so as to improve productivity in the readymade apparel-industry:

1. All materials available in time,
2. Using time and motion study,
3. Right and scientific machine lay-out,
4. Right and scientific target setting,
5. Right type of technology used,
6. Right level of worker attendance,
7. Motivated workforce,
8. Computerization of all possible works of all the departments,
9. Right material handling processes,
10. Skill and workmanship of workers,
11. Job satisfaction at workplace,
12. Good work environment,
13. Using right systems,
14. Right leadership quality of supervisors, APms, PMs, etc,
15. Right organization of materials,
16. Right quantity of high performance machinery,
17. Proper machine maintenance,
18. Continues training,
19. Minimum worker migration,
20. Using right processes.

Production Planning and Control (PPC) Department Relation with Other Departments

Introduction:

Production planning and control (PPC) plays an important role in garments manufacturing business. It’s very good news that, maximum factories are now creating PPC department. Production planning and control (PPC) has to build-up strong relationship with the other departments to achieve maximum output from the export order. As its importance in ready-made garments sector today I will present here the important relationship of production planning and control (PPC) with other departments.

Production Planning and Control:

PPC means production planning and control. Production planning and control (PPC) department is related with not only for planning garments production but also controlling the production. The main functions of production planning and control (PPC) are follow-up and execution of garment export order, job scheduling, material resource planning, facility location, loading production, process selection and planning, capacity planning, line planning, estimating quantity and costs of production.

Diagram of Production Planning and Control

Relation of Production Planning and Control (PPC) with other departments:

Production planning and control (PPC) department has to connect with various departments, those are mentioned in the below:

1. Top management,
2. Yarn department,
3. Knitting department,
4. Dyeing and washing department,
5. Garments merchandising department,
6. Commercial department,
7. Cutting department,
8. Stitching department,
9. Finishing and packaging department.

Functions of production planning and control (PPC) with all the above departments have discussed in the following:

1. Top management:

Top management consists of Managing Director (M.D) and General Manager (GM). Production planning and control (PPC) department plays an important role with the top management by providing all the information to them.

2. Yarn department:

Function of yarn department is to in-house necessary yarn depending on yarn booking chart. Here, production planning and control (PPC) department contacts with yarn department to ensure all the requirements about the yarn according to buyer’s instruction.

3. Knitting department:

Knitting department ensures all the knitting procedures according to fabric consumption chart. PPC department follow-ups the knitting department to produce required amount of fabrics in its definite time with right quality and quantity.

4. Dyeing and washing department:

It’s an important department for PPC team which dyed and washed all the knitted fabrics according to buyer’s instruction. Here, PPC team ensures the perfect dyeing shade.

5. Garments merchandising department:

Here, PPC team ensures the garments merchandising department about the overall situation of the garment export order.

6. Commercial department:

Commercial department is related with all kinds of financial support for the export order. It also deals with all the banking functions such as L/C opening, preparing shipping documents etc. Here, PPC team ensures all the financial matters by discussing with top management.

7. Cutting department:

Here, production planning and control (PPC) department contacts with cutting department to ensure all the cutting procedure in its definite item.

8. Stitching department:

Production planning and control (PPC) department contacts with stitching department to ensure the total garments production according to shipping date.

9. Finishing and packaging department:

Here, production planning and control (PPC) department ensures the perfect finishing and packaging of goods so that it can’t hamper during inspection and shipping.

Top 25 Interview Questions and Answers for Garment Job

Interview Questions and Answers:

Interview is a common scenario for any kinds of job. Each and every applicant has to face it. It can be very easy or tough which totally depends on the instant situation of viva board. During interview, you may face with your known topics or not, but you should be confident there. This article has presented some important interview questions and answers which may help you in your interview.

13. What is L/C ?

L/C means letter of credit. It is commitment by an opening bank on behalf of the importer in favor of the exporter that the bills drawn by them on the importer countries covering the shipment of specified items and quality of goods within stated period. It will be paid in exchange of documents under certain items and condition.

14. What is invoice?

After sending the garments goods to the importer country, the documents mentioning the price is sent to the buyer for collecting is called invoice.

15. What is quota?

It is an agreement between governments of the importer country and the exporter country. In details it is the quantities of garments of different categories upon the manufacturing countries according to the business policy.

16. What is FOB?

FOB means free on board. If the price of the goods is mentioned in invoice without transport cost then it is called FOB.

17. What is C&F?

C&F means cost and freight. If the price of the goods is mentioned in invoice including transport cost then it is called C&F.

18. What is CIF?

CIF means cost, insurance and freight. If the price of the goods is mentioned in invoice including transport cost and insurance cost then it is called CIF.

19. What is category?

Category is a number which indicated what type of fabric is used for making the particular garment and it also indicated the type of this garment.

20. What is face of fabric?

The surface of the fabric that is intended to be seen because it presents s better appearance than the other side due to its characteristics i.e. weaves, luster, finish etc. in many fabrics, especially industrial fabrics, face and back are identical.

21. What is faced cloth?

A term sometimes applied to the fabrics that have a separate set of warp or filling yarns on the back of the cloth i.e. pile fabric, flannel fabric.

22. What is fusing?

The term generally refers to partial melting. In bonding, fabric layers are joined together by fusion of an adhesive under heat and pressure.

23. What is the abbreviation of G/D?

G/D stands for grams per denier.

24. What is gauge?

In knitted fabrics, it is a measure of fineness or number of wales per unit of width across the fabric. Higher gauge numbers indicate finer texture.

25. What is grading?

When different sizes of patterns are made from the master pattern of the garment is called grading.

List of Garment Machine with Specifications and Functions

Garment Machine:

Garment machine or garments machinery plays an important role for making the finished product in readymade apparel industry. There are different types of garment machine used during garments manufacturing. This article has presented all the garment machine of apparel industry with their specifications and functions.

List of Apparel Machinery with Specifications and Functions:

SL No.	Name of Machine (Company Name)	Function of Machine	Remarks
01	Hand or paddle sewing machine (Butterfly, China)	Sewing the garments	Working condition
02	Industrial single needle lock stitch machine (Taking, China)	Sewing all types of fabric)	Working condition
03	2-Needle plain sewing machine (Sunsir, China)	Sewing the garments	Working condition
04	Flat  lock sewing machine (Taking, China)	Used to sew knit fabric	Working condition
05	High speed 2-Needle 5-Thread over lock machine (Taking, China)	Lock the end of fabric by sewing	Working condition
06	Over lock machine (Juki, Japan)	Secure edge of garments	Working condition
07	Button stitch machine (Consew, Japan)	Attach the button with garments	Working condition
08	Leather cutting (Taking, China)	To cut leather	Working condition
09	Embroidery machine (Consew, Japan)	Produce design with the help of thread on fabric surface	Working condition
10	Bar taking machine (Taking, China)	Making loop in the pant	Working condition
11	Kansai special machine (Hoseki, China)	Attach elastic to jacket or coat)	Working condition
12	Button hole machine (Taking, China)	Produce hole in the fabric for button attaching	Working condition
13	Snap button machine (TK-Super, China)	Manually attach repeat button	Working condition
14	Dismatic machine (Butterfly, China)	Sewing the fabric at specific design using different dick	Working condition
15	Rib cutter	Cut off rib of knit garments	Working condition
16	Collar turning and blocking machine (NGAI SHING, China)	Used for collar finishing	Working condition
17	Fusing machine (Shanghai jieshi clothing machine co. ltd., China)	Used for finishing collar lining	Working condition
18	Computerized embroidery machine (Hoseki, China)	Making design with thread by using computer	Working condition
19	Band knife cutting machine (Oshima, China)	Used to cut off fabric at small size	Working condition
20	Fashion Maker Desmatic machine (Singer, China)	Sewing the fabric at specific design using different disk	Working condition
21	Straight knife cutting machine (FJM Dalian, China)	Used to cut off fabric	Working condition