The ground floor of the Cutting Halls is designed as a fabric warehouse. Here the fabric that has been received is quickly sorted and allocated in accordance with the production graph of the respective Cutting Hall.
The sewing lines operate on the principle of Section Work, whereby each seamstress performs just one aspect of the garments production requirements, thus any mistakes can easily be spotted by the line control. This results in very accurate work over a large production, thereby maintaining the high standards set by the sample room. Production time does not stop where a machine develops a fault. That machine is immediately replaced with one of the many spare machines that are on a permanent standby. There is a number of mechanics on site that systematically check and maintain all our machines.
Only special sewing machines are used, machines that are suited to both the soft fabric and to the styles that are being produced here: flat machines 3, 4, and 5 threads, coverstitch, overlock, superoverlock button machines and eaglet machines.
Quality control of the garments is made by our own qualified staff, not only prior to shipment, but also at all stages of production. It is impossible for a production delay to occur due to insufficient cut work, as there are two large, heavily staffed, cutting halls that continuously supply the production halls with work.
The packing is always done in conformity with the customer’s delivery instructions (ratio or country allocation).Our products are finished to the point where they are ready to be sent out directly to the stores.All the trimmings are received in a central storage place from where they are distributed to all the Trimmings Areas of each Production Hall.
They are all checked against the garments physical bill of material requirements to ascertain any variance to requirements. This system enables accurate shortage reports to be created prior to production. In this way, when a garment reaches the production line there will be no surprise shortages holding up production.
Each truck is specially equipped so that throughout the journey the evanescent beauty of the garments is preserved intact.