Custom Jeans Manufacturer

How the jeans been made?

The production and sewing of jeans generally adopt assembly line operation. The whole production process includes style design, size specification and production process design, as well as material inspection, layout, laying, cutting, sewing, washing, ironing, drying,finishing and other production processes.

In order to ensure the stability of the quality of jeans products, a series of procedures need to be formulated and controlled during the production process. From fabric to cutting, the process arrangement between each process and the assembly line directly affects both input and output.

1:Pre-production

In the pre-production stage, the production order form is the original data from customer information: record jeans samples, washing color codes, whether there are corrections, precautions, etc. After the above information is checked, it will be sent to the relevant department.

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2: Technology department

Before the start of production, the sampler in the process technology department will make samples, record the production flow chart of the product, and pay attention to the precautions that are likely to occur during the sample making process. The production technology department agrees with customers to revise samples and sample clothes in order to formulate production procedures and reduce costs.

With the detailed production procedures, start the work, and provide the corrected samples to the cutting department to calculate the material consumption rate, nesting, lifting, accessories, and cutting. (After being put into production, the process technology department will immediately carry out the production of industrial plate shapes, such as: the sealing position for the crew in the workshop at the back, the plate for the front door, the plate for the ironing table.

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3: Cuttings

Cutting according to the pattern provided by the pattern designer in the craft technology department, mark and print layer by layer (it must be numbered in the order of laying, in order to prevent color difference between layers), and pack and bundle the cut pieces to the sewing workshop.

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4: Sewing

The cutted garment pieces are subpackaged and bundled and sent to the designated stations of the sewing line according to the arrangement of the craftsman. The sewing of the front and rear pieces is generally carried out at the same time, and the semi-finished products must be inspected before further sewing. In front of the lock, the same inspection must be carried out. Some individual processes, such as making belt loops, clearing sand in pockets, trimming threads, nailing rivets and snap buttons, etc., can be flexibly arranged in the process flow of the production process, making five-pocket jeans with ordinary zipper fronts, The process can be divided into five groups: making the front piece, making the front placket and zipper, making the back piece, assembling and sewing, tacking and buttonhole. (The process is flexible and changeable. It can be customized according to the requirements of the pattern and the craftsman, making the front piece, making the back piece, making the placket, tying the waistband, assembling and sewing, and buttoning the keyhole.

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A: Front Piece

The front pant process involves sewing front side, side pockets. Allocate related pieces such as left and right pockets, labels, small side panels and front pant panels to the workers to sew the front side pockets. Firstly sew the label (washing instructions and factory logo) on the left pocket, then sew the open thread on the opening of the coin pocket, and attach it to the corresponding position on the right side. Sew the bag cloth on the left and right side pieces respectively, finish the bag cloth before sewing with the front piece, fix the bag cloth and transfer the semi-finished front piece to the next group of processes.

Front panel—stitching nails—button trousers panel and left and right pocket cloths—sealing—front pleats—front side pockets—label on the left pocket—sewing coin purse topstitching— Pick it up at the corresponding position on the right side – make a pocke.

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B: Make front placket and zipper

Before zippering, the machinist should prepare the left and right placket pieces and the semi-finished front trousers piece. Sew the double-folded bottom placket, and transfer the front side to the next process. The left and right plackets and the crotch of the front piece are overlocked, the left half of the zipper tape is fastened to the left placket welt, and it is sewn with the front piece, and the molding line of the placket is sewed on the left trousers piece. Then, sew the right half zipper and bottom placket, and sew it to the right pant. The last step in this group of procedures: sewing the front crotch and topstitching. The semi-finished front piece has to pass the quality inspection before continuing to sew.

Left and right plackets and front crotch overlock seams—front seam—sewing placket molding line on left trousers—sewing right half zipper and bottom placket—sewing right trousers—sewing front crotch, Open line – quality inspection.

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C: Back piece

Workers prepare the left and right back pockets, back yokes, back pant panels and labels on the bags in advance. The first process: Use a special template to determine the shape line of the back bag and correct the size. The purpose is to draw the pattern on the bag and the width of the portion for the next process. The machinist sews the decorative line of the back pocket according to the drawn pattern, and then buckles the shape of the back pocket with an iron or a bag folding machine. Meanwhile, other machinists sew the back panels and yokes, and finally attach the back pockets and logo to the back panels. Like the front piece, the back piece semi-finished product passes quality control before continuing to be stitched.

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D: Suture

After the back pockets and placket zippers are sewn, workers start to sew the front and back panels. Sewn topstitching on the side of jeans to reinforce the fastness of the front and back panels. The waistband is then sewed, and the inseam is sewn before the welt is folded. The next process of sewing: Use the belt loop mechanism to produce belt loops of the required length and width specifications. Generally, jeans have 5 belt loops: one in the back middle seam, one on the left and right pockets of the front panel, and the other two from the front pocket to the back middle seam position between. Similarly, before entering the next process, a quality inspection must be carried out.

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E: Tack

The jeans have keyhole buttonholes at the waist and bartack reinforcement at the rear. In addition, belt loops, plackets, back pockets, crotch and other important parts should also be knotted and reinforced. Finally, sew the leather tag to the waistband.

F: Washing and packing.

The main work of the whole workshop is to clean up the ironing, thread ends, hanging tags and general inspection of jeans. After sewing, washing is an indispensable process in the production of jeans. After washing, the jeans enter the packaging workshop. Workers began to inspect it: cut off the thread ends on the front trousers and waist loops, remove the sand in the pockets, and install hidden buttons and rivets before the initial ironing and inspection. For products that pass the quality inspection, the waistline and inseam of the jeans need to be measured, after a second ironing, the hang tags, waist tags, and back pocket tags are installed, and the jeans are put into plastic bags and placed in cardboard boxes, waiting for the final inspection.

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