The fashion industry moves fast, but behind every piece of clothing is a workforce that keeps production running. While automation has transformed manufacturing, human hands are still at the heart of the process. Yet, few people stop to think about the people making their clothes or how their roles are changing.
According to the International Labour Organization (ILO), 60 million people worldwide work in the garment industry, making it one of the largest employment sectors. But as automation and sustainability reshape manufacturing, what does garment work actually look like? How are factories adapting, and what does the future hold for the people behind our clothes?
From Ideas to Production: The People Who Bring Ideas to Life
Before a garment even reaches production, it begins with an idea. Designers create sketches, but turning those ideas into actual products requires the expertise of pattern makers, material specialists, and production planners. Many major factoies now use CAD (Computer-Aided Design) software, the process has become more efficient, but human expertise is still needed to fine-tune details, test fabrics, and ensure the design translates correctly into production.
Factories play a role early on, advising on feasibility, cost, and material efficiency. Digital prototyping helps reduce waste, but human judgment remains critical, one small miscalculation in pattern-making can lead to fabric waste and costly production errors.
Fabric Preparation: Skilled Hands Behind Every Roll
Once a design is finalized, the fabric must be inspected and prepared before cutting. Factory workers ensure fabric is free from major defects like uneven dyeing, weak fibers, or texture inconsistencies. Fabric relaxing and pre-shrinking processes are crucial to prevent garments from shrinking unpredictably after sewing. Without these steps, shrinkage errors alone can cause up to 15% of production loss.
Even as inspection tools improve, many factories still rely on experienced workers to catch subtle issues that machines might miss. Spotting problems early prevents defective garments from being made, saving time, fabric, and money in later stages.
From Fabric to Form: Cutting with Precision
With fabric prepared, the next step is ensuring every inch is used wisely. Cutting is where efficiency meets precision, one misalignment can waste material and money. Traditional manual cutting can result in up to 20% fabric waste, but modern factories have reduced this with automated cutting machines and pattern optimization software.
However, automation doesn’t eliminate human involvement. Workers oversee the machines, arrange fabric layers, and adjust settings based on material type. In many factories, skilled operators ensure machines run at peak efficiency, balancing speed with accuracy. This human oversight helps maximize fabric use and minimize costly mistakes.
Bringing Pieces Together: Why Sewing Remains the Core of Production
Once fabric pieces are cut, the real craftsmanship begins. While automation has transformed many parts of manufacturing, sewing remains one of the least automated processes in garment production. A single garment can require dozens of steps, with workers assembling collars, cuffs, pockets, and zippers before the final stitching.
Sewing requires dexterity and skill. Industrial machines speed up the process, but delicate stitching and fabric handling still rely on human expertise. Research shows that sewing still accounts for 60% of total labor in garment production, highlighting the continued need for skilled workers. Automation assists by improving consistency, but fully replacing human sewers remains a challenge due to the complexity of fabric movement and variation.
Finishing Touches: Ensuring Quality Before Clothes Reach Consumers
After sewing, garments go through finishing steps such as heat pressing, labeling, and quality control. Some factories use automated folding and packaging machines, but final inspections still require human expertise. Quality control teams check for stitching accuracy, fabric consistency, and safety issues like loose threads or broken needles.
In regions with strict export regulations, 100% of garments must pass through needle detection machines before shipment to ensure safety compliance. The goal of finishing is not only to make clothes look polished but to ensure they meet brand standards before leaving the factory.
Packaging and Shipping: The Final Step in the Chain
Once garments pass inspection, they are packed and prepared for shipment. Many factories are moving towards biodegradable and recyclable packaging in response to sustainability concerns. However, challenges remain, only 9% of plastic packaging worldwide is actually recycled, meaning brands must rethink their environmental impact beyond just the product itself.
Logistics teams coordinate shipments based on global demand, often under tight deadlines. Production schedules are frequently adjusted to meet last-minute retailer requests, requiring flexibility and skilled workforce management.
Conclusion
Technology is changing garment manufacturing, but workers remain essential. Machines help reduce repetitive tasks and improve efficiency, but human adaptability, problem-solving, and craftsmanship cannot be fully replaced. The future of the industry is a hybrid model, where automation handles repetitive processes while workers focus on quality control, specialized tasks, and production oversight.
Factories that prioritize worker training alongside automation gain a competitive advantage. Skilled workers can transition into machine operation, maintenance, and quality assurance roles, ensuring that automation enhances production rather than eliminating jobs. The most successful factories will be those that balance efficiency with human expertise.
At OSHIMA, we’re all about helping garment factories work smarter, not just faster. Our automation solutions, from precision cutting to fabric inspection, are designed to boost efficiency while keeping quality high. But we believe machines should support skilled workers, not replace them.
The way clothes are made is evolving, but skilled workers are still essential. It’s not just about upgrading machines. It’s about making production smarter while valuing the people behind it. Do you agree? Get in touch, and let us know your thoughts.
