You have a new supplier. They say they can handle your order. They promise on-time delivery. But you are nervous. You have been burned before. A supplier claimed to have capacity. They did not. Your order was late. You lost sales. I have seen this happen many times. Words are cheap. You need proof. You need to verify capacity before you place the order.
Based on our experience working with hundreds of buyers, verifying a garment supplier's production capacity requires a combination of site visits, documentation review, and reference checks. For example, last year we worked with a brand from New York. They were considering a new factory. The factory claimed to produce 10,000 pieces per week. The brand asked for proof. The factory could not provide it. The brand walked away. Later, they found a factory that could. That is the importance of verification.
So, how do you verify a garment supplier's production capacity? Let me break it down. I will explain what to look for during a site visit. I will discuss documentation. I will cover reference checks. And I will give you a framework for assessing capacity.
What Should You Look for During a Site Visit?
A site visit is the best way to verify capacity. I remember a client from Chicago. They relied on photos. The photos showed a big factory. But when they visited, half the machines were empty. The factory was not busy.
During a site visit, count the number of sewing machines. Count the number of operators. For the Chicago client, we now count active machines. For woven shirts, a factory with 50 machines and 50 operators can produce 500 to 1,000 shirts per day. For knits, 50 machines can produce 1,000 to 2,000 t-shirts per day. For denim, 50 machines can produce 300 to 500 jeans per day. Also look at the cutting room. Are there cutting tables? Are there cutters? Look at the finishing area. Are there pressing stations? Are there packing tables? A factory with full lines is a factory with capacity. A factory with empty space and no workers is not.
Also look for work in progress (WIP). Are there bundles of cut fabric waiting to be sewn? Is there finished goods waiting for packing? WIP indicates active production.
What Is the Ratio of Machines to Operators?
Ideally, each machine has an operator. If you see 100 machines but only 50 operators, the factory is not at full capacity. For a sportswear client, they visited a factory with 80 machines and 80 operators. The factory was busy. They placed an order.
How Do You Assess Cutting Capacity?
Cutting capacity is often the bottleneck. Look for:
- Number of cutting tables
- Number of cutters
- Automated cutting machines (computer-controlled)
- Fabric storage (is there fabric waiting to be cut?)
For a denim client, they saw 4 cutting tables and 8 cutters. The factory could cut 2,000 jeans per day.
What Documentation Should You Review?
Documents tell the truth. I remember a client from Boston. The factory claimed they had open capacity. But their production schedule was full for 3 months. They were lying.
Ask for the production schedule. For the Boston client, we now review the schedule. For woven shirts, the schedule shows which orders are in cutting, which are in sewing, and which are in finishing. A factory with open slots in the next 2 weeks has capacity. A factory with no open slots for 2 months does not. Also ask for the order book. How many orders are pending? What are the quantities? A factory with 10 orders of 10,000 pieces each is busy. A factory with 2 orders of 500 pieces has capacity. Also ask for the factory's lead time. If they say 4 weeks for bulk, but their schedule shows 8 weeks, they are lying.
At Shanghai Fumao, we share our production schedule with clients. We have nothing to hide.
What Should a Production Schedule Show?
A production schedule should show:
- Order number and customer
- Style and quantity
- Cutting start and end date
- Sewing start and end date
- Finishing start and end date
- Packing and shipping date
For a sportswear client, they reviewed our schedule. They saw open slots in 2 weeks. They placed an order.
What Is a Realistic Lead Time?
Realistic lead times for bulk:
- Simple knits (t-shirts): 3 to 4 weeks
- Woven shirts: 4 to 6 weeks
- Denim: 6 to 8 weeks
If a factory promises 2 weeks for denim, they are likely lying or they will rush the order. For a denim client, a factory promised 3 weeks. The order was late. The client switched to us.
How Do You Use Reference Checks?
References are the best proof. I remember a client from Seattle. They asked for references. The factory gave them 3. All 3 said the factory delivered on time. The client placed a large order.
Ask the factory for 3 references. Call them. Ask specific questions. For the Seattle client, we now ask: Did the factory deliver on time? Was the quality good? Did they communicate well? For woven shirts, ask about the factory's ability to handle complex styles. For knits, ask about their speed. For denim, ask about wash consistency. Also ask about the factory's capacity during peak seasons. A factory that struggles in Q4 may not be reliable for your fall order. A reference that has worked with the factory for 2+ years is more valuable than a new reference.
At Shanghai Fumao, we provide references. Our clients are happy to speak about us.
What Questions Should You Ask References?
Ask:
- How long have you worked with this factory?
- What was your order quantity and lead time?
- Did they deliver on time?
- Was the quality consistent?
- How did they handle problems?
- Would you use them again?
For a sportswear client, they asked these questions. The references were positive. They placed an order.
How Many References Should You Check?
Check at least 3 references. If the factory has been in business for less than 2 years, ask for more. For a denim client, they checked 5 references. All were positive. They felt confident.
What Red Flags Indicate Low Capacity?
Red flags save you from mistakes. I remember a client from Denver. They ignored red flags. The factory was empty. The owner claimed they were between orders. The client placed an order. The factory was late.
Red flags include empty machines, no work in progress, a production schedule that is blank or hidden, references that are vague or unwilling to talk, and lead times that are too good to be true. For the Denver client, we now look for these red flags. For woven shirts, an empty sewing line is a red flag. For knits, no fabric in the cutting room is a red flag. For denim, no washing machines running is a red flag. Also beware of factories that are too busy. If the schedule is full for 6 months, they may not have capacity for your order. They may rush it. Balance is key.
At Shanghai Fumao, we are transparent. We show you our schedule. We tell you our lead time. We do not overpromise.
What Is a "Too Busy" Factory?
A factory that is 100% booked for the next 3 months may still take your order. But they will rush it. Or they will outsource it. For a sportswear client, a factory took their order but outsourced it to a lower-quality factory. The goods were poor.
What Is a "Too Empty" Factory?
A factory that is 80% empty may lack orders for a reason. Their quality may be poor. Their prices may be high. For a denim client, they visited an empty factory. The owner claimed they were "between seasons." The client ordered. The quality was poor.
Conclusion
Verifying a garment supplier's production capacity requires a site visit, documentation review, reference checks, and your own calculation. Look for active machines, work in progress, and a realistic production schedule. Ask for references and call them. Calculate capacity yourself. Watch for red flags: empty factories, hidden schedules, or promises that are too good to be true.
At Shanghai Fumao, we welcome verification. We have active production lines. We share our schedule. We provide references. We help you calculate. We do not overpromise.
Let us prove our capacity. Contact our Business Director, Elaine, directly at elaine@fumaoclothing.com. Schedule a site visit. We will show you our factory.
