You’ve found a potential clothing manufacturer with “5 production lines” listed in their brochure. Sounds impressive, right? But what does that actually mean for your order? Can they handle 10,000 units in 4 weeks—or just 1,000?
Evaluating production capacity is about more than counting sewing machines. It’s about understanding speed, labor, quality flow, and load balance.
As a Chinese clothing manufacturer with exactly 5 lines, I can break down what you really need to ask, inspect, and validate before trusting a factory with your brand’s future.
What Does “5 Production Lines” Really Mean?
When a factory says it has “5 lines,” don’t take it at face value. Not all lines are created equal.
Production lines vary in manpower, machinery, shift length, and layout efficiency. Understanding their real output requires detailed questions.
How Many Workers and Machines Are in Each Line?
A typical line has 15–25 workers and 20–30 machines depending on complexity. Ask:
- Is each line dedicated to a product type (e.g., woven shirts vs. knits)?
- Are lines modular and interchangeable?
- How many shifts are run daily?
Use a checklist like this one from Maker’s Row to dig deeper.
What’s the Average Output per Line per Day?
As a benchmark:
- Basic T-shirt: 500–800 units/day/line
- Polo shirt: 300–500 units/day/line
- Dress shirt with trims: 150–300 units/day/line
We share output logs with clients to show our daily capacity. If a factory claims 10,000 pcs/day, ask for production reports or past PO references.
How Can Factory Layout Affect Output and Lead Time?
Production capacity isn’t just about equipment—it’s about how efficiently the floor is managed.
A streamlined layout with minimal bottlenecks enables faster lead times and consistent quality across high volumes.
What Are Key Areas to Inspect in a Factory Tour?
Focus on:
- Cutting room: Is it manual or digital?
- Sewing lines: Are there bottlenecks?
- QC stations: Are inspections in-line or post-sewing only?
- Packing area: Is space sufficient for large orders?
We use a U-shaped workflow that minimizes fabric backtracking and enables multi-style batching—ideal for private label clients.
What Technology Improves Layout Efficiency?
Ask about:
- Auto-spreading and cutting machines (Gerber, Lectra)
- Real-time order tracking via ERP
- Fabric barcode systems
- In-line finishing tools (e.g., fusing, sleeve press)
Factories using Lean Manufacturing principles are more productive and consistent in bulk orders.
What Metrics Prove a Factory’s Capacity is Real?
Forget vague promises. What you want is proof—numbers, charts, and history.
Factory KPIs like efficiency rate, daily capacity, and line utilization offer objective insights into production reliability.
What KPI Data Should You Request?
- Efficiency rate (%): Target >75% for consistent factories
- Line utilization (%): Are all lines fully booked or underloaded?
- Style changeover time: How quickly can a line switch styles?
- Daily rejection rate (%): Should be below 2.5%
We share these KPIs weekly with clients to ensure transparency. Tools like Factory OS or even Google Sheets can help manage expectations.
Can You Cross-Check Capacity With Order History?
Yes. Ask:
- How many styles per month do you complete?
- What’s the largest order shipped in the past 6 months?
- Can I see a reference PO from a past client?
We offer anonymized shipping logs and allow clients to speak directly with repeat buyers as a credibility check.
Why Does the Sampling and Bulk Ratio Matter?
A factory might produce great samples—but struggle with scaling. The transition from sample to bulk is often where delays begin.
Your factory must prove they can replicate approved samples at scale, across all 5 lines with consistency.
What’s a Healthy Sample-to-Bulk Process?
Here’s our standard flow:
- Client approves a prototype sample
- We create a PP (pre-production) sample using actual fabric, print, and trims
- PP sample is signed and referenced during bulk production
- Inline QC uses PP sample as benchmark across all lines
This ensures consistency, especially if lines operate in parallel.
How to Evaluate Their Bulk Production Confidence?
Ask:
- Do you offer “pilot runs” before full launch?
- Are line leaders briefed with visual guides and PP samples?
- Do you allow third-party inspections?
Factories confident in their scalability welcome outside QA like QIMA or TÜV SÜD—we do too.
Conclusion
“5 lines” means nothing if you don’t know what those lines are producing, how fast, and how well. Vetting production capacity requires numbers, walk-throughs, metrics, and trust. As a factory that supports U.S. brands at scale, we believe in transparency, traceability, and consistency from first sample to full shipment.
At Fumao Clothing, our 5 lines are optimized, audited, and built for scalable, high-quality manufacturing. Whether you're launching 1,000 pcs or scaling to 50,000, we can walk the talk—and show you the floor to prove it.
