GCSE Textiles

> To ensure good quality products are manufactured efficiently at a profit

> Designers work with clients and manufacturers -  all need to keep needs of consumer in mind

> identifies the need for a product through market research and uses this to provide a design brief for the designer

> set production deadlines and the price of the product

> usually a manufacturer or retailer

> works to the design brief and researches market trends, fabrics and processes

> takes into account any relevant societal, cultural, moral, environmental or safety issues

> produces a design specification, product costings, and helps plan manufacturing

> uses models or prototypes made by the designer, and works out the most efficient way of manufacturing the product

> produces a production plan and a work schedule

> during manufacture they aim to keep material and labour costs down, while producing a high-quality, safe product on schedule in a safe environment

> demands a product that meets their requirements: a high-quality, value-for-money and safe product

> all production systems consist of inputs, proccesses and outputs

> feedback loop = enables inputs and processes to be modified, e.g. a result of feedback from consumers and quality control checks

> can be modelled with a system diagram

> In a production system, a number of different processes or subsystems take place at the same time.

Examples:

> Lay planning: involves laying out pattern pieces of a fabric to work out the quantity and cost of material

> Costing: involves estimating how much each product costs to make, including materials, labour, rent and energy costs

> Quality control: involves the checks for quality that take place at all stages

• A single product is designed and made to a client's specification
• Example = made to measure wedding dress 

Advantages: 

• Perfect fit, hight skilled, created to persons style, unique design, high standard, desirable characteristics

Disadvantages: 

• Expensive to make, high labour cost, only one, labour intensive, only wear once, designer ill = production issues, designer must have a wide range of skills

• Set quantites of aproduct are manufactured to order
• Quantity varies from a set of four cushions made by a designer/maker to 20,000 jumpers made for a department store.
• Number of products could be made to meet seasonal demands

Advantages

• fashionable, designed to fit a range of shapes and styles, fairly cheap, low manufacturing costs

Disadvantages:

• comes in and out of fashion quickly, not always a perfect fit, standard size, garment could be wasted if not sold, company might lose out on profit if products go in the sale

> Manufacturing of a large number of identical products over a long period of time. They are usually uncomplicated and can be made cheaply. Standardised production methods mean it is suitable for products that rarely need to be redesigned. Used for products that are needed in very large numbers, eg socks or jeans

Advantages:

• products are made overseas where labour costs are lower, cost effective fabric, basic items, never goes out of fashion

Disadvantages: 

• Overseas production = increase in costs = not environmentally friendly, not sustainable = mostly synthetic fabric used, child labour issues/not always ethical, simple design/basic items, standard sizes

> Just-in-time manufacturing is when materials are ordered so they arrive just as they are needed

• > Preparation stage: the amount of materials to buy-in. Preparation of garment patterns, templates and lay plans.
• > Processing stage: fabric spreading, cutting, labelling and bundling of fabric pieces.
• > Assembly stage: instructions for fusing, joining and pressing the separate parts.
• > Finishing stage: instructions for decorative/functional finishing and final pressing.
• >Packaging stage: how to label, hang, fold and cover the product ready for transport.

> Computer software is used to produce the production plan

• order of assembly
• stitch type
• processes to be used
• time taken
• seam allowance

• Textiles designs are stored electronically to ease repeat printing orders.
• Processes such as colour matching, dye weighing and fabric printing can be automated.
• Designs and information can be sent electronically on a global scale.
• CAD and CAM can be used to enhance accuracy of repetitive identical production.

• Initial set-up costs of machinery and programming can be high, but manufacturers benefit from cheaper costs, efficient production and standardised quality.

• Computer-numerical control (CNC) machines are used for:
• printing
• cutting
• joining and other processes.
• CNC-automated machines can repeat processes with accuracy and reliability, and are easily re-programmed when changes are needed. 

• picking up fabric from store room
• spreading and cutting fabric
• labelling and transporting cut fabric pieces for assembly
• moving cut fabric pieces around the factory on an overhead conveyor
• automating processes like buttonholing or embroidery