Manufacturing

Please view our Custom Manufacturing Booklet with 4 easy steps.

GETTING STARTED – PATTERN AND SAMPLE MANUFACTURING PROCEDURE

The process starts with making a first pattern and sample. The best situation is when a client has a finished pattern and a tech pack. If you only have a concept, picture of the model or a sketch, it will take longer. Having a sample or similar garment on hand is a good start.

A. Pattern Making (3 to 10 Business Days)
If you don’t have a pattern, we kindly help you to make one. We must make a pattern of your garment before we can make your first sample. Additionally, every time you adjust or alter your garment, the pattern has to be adjusted.

B. Sample Manufacturing (6 to 10 business days)
When we make your first sample, we are primarily concerned with the fit. We send you the sample and the measurement lists, you notify us of your adjustments, and we make another sample until we nail the fit down. Pinning, cutting, taping and otherwise marking your sample and returning it to us is a good method of communicating your adjustments. Include as many notes and sketches as necessary. Minor revisions may be made without the need for re-sampling. While we are manufacturing your samples we have to keep going on the fabric approval to.
Once the sample is finalized, we make a production sample. The production sample is exactly what your production will look like, and becomes the benchmark and standard. Production sample protects you from receiving a different model. When you receive the full order, you have a pattern to check the quality and other details. If the full order is not exactly as same as production sample we kindly take our products back and start re manufacturing your order.

Please note that on first samples we often use substitute fabrics in order to keep your costs down. For example, this would be true if you were intending to use a custom knitted fabric, a particularly expensive fabric, or a special order fabric. Original fabric, accessories will be used with production sample.

DEPOSIT AND PAYMENT
A deposit of 60% of your gross order is required when the customer approves the production sample. The remaining 40% is due prior to shipping. We accept check, Money Orders and wire transfers. A deposit will be required to begin pre-production pattern and sample making. The deposit amount will be determined after we provide you with an initial estimate. Once your production deposit is received we will contact you with your production completion date. Please note that if you are ordering special or having a mill knit your fabric, the completion date may vary.

PRE-PRODUCTION

A. Production Approval

Production approval is provided in the form of a Purchase Order, which is called a PO for short. Production cannot proceed until we receive your written, faxed, or emailed PO and orders to proceed. Your PO should include…

*The style number
*Sizes and Quantities
*Fabrics and Colors
*Any special instructions
*Price

Cancellations cannot be accepted after a PO has been submitted and production has begun.

B. Labels and Hangtags
Labels are custom items that the client needs to provide these information’s to us while we are manufacturing your production sample. This phase has to work with the sample production procedure since it involves artwork and requires several approvals. We will be happy to provide you sample labels and hangtags which you can choose from.

C. Care Labels and Size Tags
We use generic size labels and hang tags. If you want woven or custom care labels, please let us know. This phase has to work with the sample production procedure since it involves artwork and requires several approvals. We will be happy to provide you sample labels and hangtags which you can choose from.

PRODUCTION

A. Delivery, Turnaround, and Lead Times
A guideline for turnaround and delivery is 4 to 8 weeks, if you have a basic production with few embellishments and are using stock fabric. Embellishments, dyeing and milling fabric adds 2 to 4 more weeks to your production.

B. Grading, Sizing and Marking (1 to 3 business days)
After having reviewed and approved the sample, we grade the pattern according to your grade rules. We can assist you with deciding what size and grading scale to use. After deciding what grading scale and size range are to be produced, we proceed with getting your marker printed. The marker is the template used to cut your fabric.

C. Cutting (1 to 3 business days)
Once you have made your deposit and submitted a PO, we will purchase your fabric, print your marker, and begin cutting. Generally, no changes to your PO can be made after cutting begins.

D. Sewing (10 to 17 business days)
Sewing follows cutting unless you garments are receiving special treatments such as dyeing or embroidery.

E. Quality Control
Our Quality Controllers monitors every manufactured product (%100) before packing. In order to control that each process for conformity to standards and specifications. Quality control audits are conducted after every step of the manufacturing process.

F. Packaging
This step involves trimming, tagging, steaming and ironing, folding or hanging, and a final quality control check to ready your garments for delivery. We offer custom Packing that you can choose your bag type, your logo on the garment bags, box type, your logo on the boxes etc. from our various packing samples. Please provide any special instructions on how you would like your product finished before your production sample approval.

G. Independent Audits
When your products are ready to ship, our independent Audits will randomly check %30 of your products. These Audits are independent. This means even the general manager or the owner has no rights to interfere their process and judgments.
The procedure is as follows:

1- They will randomly check %30 of the boxes. (Dimensions, weight, onbox stickers and the inner pieces as if they are mentioned as same as on the box stickers.)

2- They will randomly choose %30 of the packed garments and open them to check their bags, folding type, quality, look, accessories to see as if they were manufactured as your standards and specifications.

3- Audits will measure %30 of your garment to see as if they were manufactured as your standards and specifications.

If the Audits will find more than %2 problems with the checked garments, they order to open and check all your products according to their critics.
After the check, they will audit again.

H. Working Loss and Over Cuts
Each stage of production may result in some loss and substandard work that must be culled during quality control and Audit check. In anticipation of this, we will cut and sew a few extra pieces. You can expect your final production to be within 5%, plus or minus, of your expected count. In the event that we manufacture a slight overage, it is expected that the customer will accept it.

SHIPPING

A. Terms and Carriers
We offer to ship your products by air. An air shipment takes about 3 to 6 days. (Depending where you located)
All merchandise will be shipped directly from Turkey to the nearest airport. Airfreight fee is included in the price.

B. Customs Clearance and Delivery
Organic Apparel will custom clears your products and delivers your products to your address at your cost.
Custom tax for textile products will be between %2 to %18 of the total merchandise value.
Delivering your products to your address will be between 300$ to 800$

C. Notice of Claims
Notice of Claims such as shortages or quality problems must be submitted within 5 days of receipt of the goods. Claims may not be submitted if the client has altered the goods. Examples of these alterations include dyeing, printing, embellishing, cutting and sewing. All claims must be submitted in writing.

D. Returns and Credit
After evaluating a claim, Organic Apparel USA may authorize a return by issuing a Return Authorization (“RA”). Returns are not accepted without an authorization. We will not accept any merchandise claims if additional processing has altered the garments. Credit may be issued upon receipt of goods and inspection by the Organic Apparel USA quality control staff.

SERVICES

A. Fabric Sourcing and Custom Milling
There are two options in terms of how we manufacture your fabric. The first option is “Grade A” fabrics that are readily available in our stocks. This option works best with smaller quantities since it is one of the quickest and least expensive methods.

Your second option is to have the fabric you want custom knit and dyed. The minimum is generally 500 yards, and that yardage can be dyed two or three colors. This option is best when a specific blend, weight, and texture are desired.

B. Our Dye House Services (4 to 10 business days)
Piece dyeing, garment dyeing, and a variety of washes and rinses are available to our Particular Brand customers. Color matches are achieved through dyeing to match and lab dipping.

Piece dyeing is dyeing the fabric before sewing. Garment dyeing takes place after the garment is sewn.

Lab dipping is how an exact match and custom color is accomplished. Dyeing to match is quicker but less precise. Colors are matched to swatches, samples, or Pantone Colors provided by you. (Swatch cards from the paint department of your favorite hardware store work well.)

The dye house is also an industrial laundry that uses rinses and washes to give your garment a distinctive look and feel. Just like jeans, many fabrics can be stone washed, mineral rinsed, and enzyme rinsed to make them softer and more distinctive.

Lace, ribbon, cord, tape and various trims can all be dyed to match your garments.

C. Buttons, Snaps, Rivets, Zippers, Lace, Ribbon, Trim, Tape, and Notions
We offer custom manufacturing to your accessories. You can customize your logo and brand name on your accessories. Please keep in mind that some accessories have minimums for customizing. If you need our help on customizing we will send you sample accessories that you can choose from our various samples.

D. Embroidery, Silk Screening, and Additional Services
Embroidery, silk screening, laser engraving, embossing, and other embellishments are all available. Please keep in mind that artwork involves numerous approvals and will lengthen your time lines.

A FEW EXTRA POINTS TO KEEP IN MIND

* All Purchase Orders, adjustments, and other directives for both sample making and production, must be received by mail, email, or fax and in explicit terms.

* Precise quotes can be difficult to provide during the initial phases of pre-production, especially if many variables remain undetermined. Some of the variables that will determine production costs include fabric, cost of sewing, trims and notions, and other inputs. Early quotes are often ballpark figures until the details have been determined. The accuracy of our quotes increases as the inputs of your garment are finalized.

* Each time you make an alteration to your production sample, your delivery date will likely be delayed.

* Production takes from 4 to 10 weeks. We know we mentioned this earlier. Please keep it in mind.

PLEASE CONTACT US HERE or CALL US AT 786-216-5311 FOR ADDITIONAL INFORMATION OR SPECIFIC QUESTIONS !