Operations

Our operation is based mainly on a piece rate bundle system.  We do employ the use of a line system in some cases depending upon the item and quantity of order.  Our normal minimum order quantity is 10,000 pairs.  We are completely computerized and use a sophisticated bar code system to track all production and payroll.  Our turn time is generally three weeks on average from receipt of the goods or the date cut.  This, of course, depends upon the style and it’s particular requirements.

After receiving cut work, or cutting it ourselves, it is bundled, shade marked and made ready for small parts.  Flies, belt loops, bands, and flaps are prepared in part’s sections.  From there it moves to the main production lines and then on to finishing where belt loops, buttonholes and buttons are attached.  After finishing, the work is trimmed, baked (if required) and pressed.

Cutting Room

Production Lines

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Aside from the machine operators, each section has one supervisor who is
responsible for the production and quality in his/her section.  Each section has
additionally one assistant supervisor, one or more distributors, two or more roving
quality checkers, one person measuring bands at the machine, one person matching
panels to insure proper shading, one person marking sizes before banding, one
person checking the chained seams for skips and two final inspectors.  At the ends
of the sections, we employ auditors that move from section to section doing random
audits based on a 1.5 AQL.  Work may not proceed to the next section unless it
passes this audit.  These auditors have independent authority to stop a line
temporarily from producing if need be.  All operators fix their own repairs at their
own expense.  All production can be traced to the original operator at any time in the
production process.  Our computer system can also track operators and operations.
After pressing, work in process moves on to the final inspection.  We again 100%
inspect every garment, measure every waist and inseam and check every label.  
Each pair that is passed contains the inspector’s number.   A rejected garment is
repaired, re-pressed and re-inspected.  Once passed, garments move on to
packing.  We do all ticketing, tagging, bagging, hanging and prepacking there
depending on the needs of the cut.  
After packing, a full audit based on a 4.0 AQL is done on each cut.  If rejected, the cut
goes back for 100% inspection and repair and is audited again.  Quality is our main
priority and we have an extended quality staff of checkers, inspectors and roving
auditors in each section.  All quality data is written down and kept on file for future
reference. Quality Reports such as in-line and end-line quality reports, in-line and
end-line repair reports, stitches per inch reports, final quality audits, spec reports,
packing audits and irregular reports are obtainable through the Island Apparel
Quality Control Guidelines.  Copies of most of these are also sent to the customer.  
We do our utmost to make a quality garment as well as meet the delivery needs of
our customers.

H O M E