Process
Our Seamless Process: From Concept to Creation
At FA Home & Apparel, we follow a structured and meticulous process to ensure that every product we create meets the highest standards of quality, innovation, and craftsmanship. From selecting the finest fabrics to the final finishing touches, every step is optimized for efficiency, precision, and excellence.
Organized Fabric Storage
We maintain a well-structured fabric storage system, ensuring easy access to a diverse range of textiles. Our streamlined organization enables quick retrieval and efficient workflow, allowing our designers and production teams to work seamlessly. This system also supports continuous research and development, giving our team the flexibility to explore new fabrications and techniques.
A Digitized Warehousing & Archival System
Our dedicated warehouse unit is fully digitized, ensuring smooth inventory management and real-time tracking of fabric stocks. Additionally, our extensive archival system is also digitalized, allowing us to preserve and access past collections effortlessly. This not only helps maintain consistency in production but also serves as a valuable resource for innovation and design evolution.
An Important Cog
From knits to woven, our repositories contain fabrics for all our manufacturing needs, be it a high quality garment or a fine piece of home textile. We store the finest fabrics not just for fabrication, but also to support constant research, development and testing of new designs and ideas. Fabrics in storage are organized to minimize wastage and help us make effective and efficient use of our resources.
Rigorous Quality Assurance
Quality is at the heart of everything we do. Before moving forward in the production process, every fabric undergoes a rigorous inspection to ensure it meets our stringent quality standards. By identifying and addressing potential defects at an early stage, we uphold the integrity and longevity of our final products.
In-House Testing Lab
Our fully operational, compliance-approved in-house lab at our Head Office meets international standards and is staffed with experienced professionals. To maintain consistent color accuracy and fabric performance, we use a spectrophotometer to test textile pigments. Additionally, we conduct a range of tests By incorporating these quality control measures, we ensure that every product meets international standards before it reaches our customers.
Fabric Relaxation
To maintain the integrity and stability of our fabrics, we subject them to a controlled relaxation process before cutting. This step allows the fabric to regain its natural shape, preventing shrinkage or distortion in the final product.
Climate-Controlled Relaxation Rooms
Our relaxation process takes place in a controlled environment, ensuring the fabric settles naturally before moving on to the cutting stage. This minimizes inconsistencies and ensures a perfect fit for every garment and home textile product we manufacture.
Unroll & Stabalize
Keeping fabrics in a relaxed mode from opening the tie and cover, is done in natural temperature. Fabrics relaxation means relaxing fabrics from its roll-type tie. Relaxation is very important to get fabric’s own shape, garments measurements depend on proper fabrics behavior. Relaxation is also necessary for stretch fabrics. The objective of fabric relaxation is to keep fabric’s dimensional stability intact. Fabric relaxation time depends on the fabric’s nature and customer requirements.
Precision Cutting with Advanced Technology
Accuracy in cutting is crucial to achieving a flawless final product. We use Computer-Aided Design (CAD) and laser-cutting technology to ensure every piece is cut with precision. This eliminates errors, reduces material wastage, and guarantees uniformity in production.
State-of-the-Art Cutting Techniques
Our advanced CAD-based pattern-making software allows for precise digital pattern creation and efficient fabric utilization. Additionally, laser and automated cutting machines ensure each piece is cut to perfection, reducing human error and improving efficiency in bulk production.
Expert Fabrication
Our team of skilled artisans and technicians brings each design to life with meticulous craftsmanship. Using a combination of traditional techniques and modern machinery, we ensure that every stitch and seam is executed with precision.
A Blend of Traditional Craftsmanship & Modern Machinery
We employ a variety of specialized high-speed sewing machines, overlockers, and hemming units to achieve flawless stitching and durability. Our skilled workforce ensures every piece is assembled with precision, reflecting our commitment to craftsmanship and excellence.
State Of The Art Facilities
Our facilities are equipped with state of the art sewing and finishing equipment which includes Automated Bottom Hemming, Placket Sewing, Computerized Single NDI Lock Stitch w/ Rear Puller, Pattern sewing, wide belt fusing machines, Sewing machines. The product assembly process is broken into smaller units called operations. Each operator is given one or more operations to do. The piece is passed from one operator to the next operator in a predetermined pattern enabling the total assembly of the product.
Finishing, Folding & Packaging
Every product undergoes a meticulous finishing process to ensure superior quality. From trimming excess threads to steam ironing, we refine every detail before packaging.
Attention to Detail in Every Step
- Finishing: Thorough quality checks, thread trimming, and ironing for a polished look.
- Folding & Packing: Each item is carefully folded and packed to maintain its pristine condition during transit.
- Sustainable Packaging: We prioritize eco-friendly packaging solutions that align with our commitment to sustainability.
Packaging of products is done in many ways. Some product, i.e: garments, are hanger packed (coats, jackets, suits, children’s dresses etc) and some are fold packed (shirts, t-shirts, track suits, etc.) The type of packaging is dependent on the specifications of the buyer, the display techniques at point of sale, the volume of products, etc.