PLM vs. Traditional Apparel Production: A Comparison

---

If you work in the apparel industry, you know how complex and challenging the design and production process can be. From ideation to sourcing, sampling to manufacturing, and quality control to distribution, there are many steps and stakeholders involved in bringing a product to life.

But how do you manage all these aspects efficiently and effectively? How do you ensure that everyone is on the same page, that deadlines are met, that costs are controlled, and that quality is maintained?

Traditionally, many apparel companies have relied on manual methods, such as spreadsheets and paper-based systems, to manage their product development process. However, these methods have many limitations and drawbacks, such as:

• Lack of visibility and collaboration

It can be hard to keep track of who is doing what, when, and why. Information can be scattered across different files, folders, and platforms. Communication can be slow and inconsistent. Errors and misunderstandings can occur easily and frequently.

• Inefficiency and waste

It can take a long time to create, update, and share documents and data. Changes and revisions can be cumbersome and time-consuming. Duplicate work and rework can be common. Resources can be wasted on unnecessary tasks and activities.

• Low quality and compliance

It can be difficult to ensure that the design specifications are followed accurately and consistently throughout the production process. Quality issues can arise due to human error or miscommunication. Compliance with industry standards and regulations can be overlooked or neglected.

These problems can result in delays, cost overruns, customer dissatisfaction, and loss of competitive advantage. That's why more and more apparel companies are turning to PLM (Product Lifecycle Management) software to streamline and optimize their product development process. PLM software is a digital platform that enables you to manage all aspects of your product lifecycle in a centralized, integrated, and collaborative way.

Here are some of the benefits of using PLM software for your apparel business:

• PLM software increase visibility and collaboration. You can create a single source of truth for all your product information and data. You can share and access information in real time across different teams, departments, locations, and partners. You can communicate and coordinate effectively with all stakeholders involved in the product lifecycle.

• PLM software helps fashion companies save money in the long run by reducing operating costs, improving productivity, and increasing margins. By using PLM software, fashion companies can eliminate errors, rework, delays, and waste that result from manual methods. They can also bring products to market faster than competitors, identify best sellers and worst performers, and optimize pricing and discounting strategies to sell more products at full price.

• PLM software enhance quality and compliance. You can ensure that the design specifications are followed throughout the production process. You can detect and resolve issues early and proactively. You can comply with industry standards and regulations. You can deliver high-quality products that meet or exceed customer expectations.

• PLM software provides comprehensive and accurate reporting on any data point that you want to collect. It also allows you to customize your reports according to your specific needs and preferences. You can choose what data you want to see, how you want to see it (e.g., charts, graphs, tables), and who you want to share it with (e.g., internal teams, external partners). You can also generate reports automatically or on demand at any stage of the product lifecycle.

• PLM software also integrates with other tools that fashion teams use for different functions. For example, PLM software can integrate with communication channels (e.g., email), graphic design plugins (e.g., Adobe Illustrator), point-of-sale systems (e.g., Shopify), enterprise resource planning systems (e.g., SAP), etc. These integrations help fashion teams be more efficient and consistent by avoiding data duplication or inconsistency.

Here's a visual graph that shows a detailed comparison of the traditional way of managing apparel production versus how a PLM solution works.

Aspect	Traditional Apparel Production	PLM Solution
Collaboration	Limited collaboration between teams; communication often relies on emails and phone calls.	Enhanced collaboration with a centralized platform for all teams; real-time updates, comments, and document sharing.
Data Management	Relies on paper-based or Excel systems, making it difficult to track changes and versions.	Centralized digital repository for all product-related data, including designs, specifications, and revisions.
Design and Development	Sequential process where designs are created, then handed off to production. Iterations are time-consuming.	Concurrent design and development, allowing multiple teams to work on different aspects simultaneously, reducing time to market.
Supply Chain Visibility	Limited visibility into the supply chain, making it challenging to track materials, orders, and deliveries.	End-to-end visibility across the supply chain, enabling efficient tracking of materials, orders, and production progress.
Compliance Management	Compliance checks are often manual, leading to potential errors and delays.	Automated compliance checks and alerts to ensure products meet regulatory standards, reducing the risk of non-compliance.
Prototyping and Sampling	Manual creation of prototypes and samples, often leading to rework due to miscommunication.	Digital prototyping and sampling, allowing virtual testing and visualization, reducing the need for physical samples.
Change Management	Changes require extensive communication and coordination, leading to delays and misunderstandings.	Streamlined change management processes, allowing quick updates and revisions with notifications to relevant stakeholders.
Cost Management	Cost estimation and tracking can be inaccurate due to reliance on disparate systems.	Accurate cost tracking and analysis, integrating cost data with product information for better decision-making.
Market Responsiveness	Slow response to market trends and customer demands due to lengthy production cycles.	Agile response to market trends, enabling quick adjustments to designs and production based on real-time insights.

As you can see from this comparison, PLM software offers many advantages over traditional methods in apparel design and production. While traditional methods of apparel design have served the industry for decades, PLM software offers a plethora of advantages that can no longer be ignored. From enhanced efficiency and collaboration to fostering creativity, managing costs, and ensuring adaptability and sustainability, PLM software has become a cornerstone of success in the modern fashion landscape. By embracing this technology, fashion companies can not only streamline their processes but also unleash their full creative potential, ultimately delighting customers and thriving in the competitive market.

If you are interested in learning more about PLM software and how it can help your fashion business, you can check out 3 Clicks Cloud. You can request a demo then a free trial to see how it works in action.