Common Tech Pack Mistakes That Delay Clothing Production.
Ten avoidable mistakes that add sample rounds, inflate costs, and push timelines - with exactly how to fix each one.
General industry knowledge • Reviewed by Fenalt editorial team
The 10 Mistakes
What Causes Production Delays - and How to Avoid Them
Missing or Incomplete Measurements
Impact
The most common cause of first-sample rejection. Without a complete POM (points of measure) table, the manufacturer must estimate measurements - or copy a standard sizing chart that may not match your design intent.
How to Fix It
Include a full measurement spec table covering every measurement point for every included size, with tolerance columns. Specify how each measurement is taken (e.g. 'chest: 1" below armhole, laid flat, total width').
Vague or Missing Fabric Specification
Impact
Without a clear fabric specification, the manufacturer sources whatever is available and close to your description. The first sample arrives in fabric that may have the wrong weight, texture, or hand-feel.
How to Fix It
Specify: fabric composition (e.g. 100% combed cotton), construction (single jersey, French Terry, etc.), weight range (e.g. 280–320gsm), and finish (pre-shrunk, mercerised, etc.). Include a physical swatch if possible.
Colour Given as a Name Rather Than a Reference Code
Impact
Colour names like 'forest green' or 'dusty pink' are interpreted differently by every mill and factory. The colour in your sample will not match your expectation.
How to Fix It
Always specify colour using Pantone (PMS) codes for solids, or request a lab-dip approval (the factory dyes a swatch to your target and you approve before proceeding).
Print and Embroidery Placement Described in Approximate Terms
Impact
'Centre chest' is not a placement instruction. Without precise coordinates (measured from a reference seam), placement will vary between samples and between production units.
How to Fix It
State placement as exact measurements from reference seams: e.g. 'Centre front chest print: 12cm from collar seam, centred on chest seam to seam width.' Include a placement diagram.
No Bill of Materials (BOM)
Impact
Without a BOM, the manufacturer makes assumptions about trims - zipper type, zip pull style, drawcord material, label positioning, button size. Every assumption is a potential revision.
How to Fix It
List every component with specification: main zipper (e.g. YKK #5 nylon coil, auto-lock pull, antique brass), drawcord (6mm flat cotton, matching body colour), main label (woven neck label, 5cm x 2.5cm, own artwork supplied).
Tech Pack Not Updated After Design Changes
Impact
Design iterations happen during development. If the tech pack is not updated to reflect each change, manufacturers work from outdated versions. Conflicting versions cause mislabelled samples and QC disputes.
How to Fix It
Version-control your tech pack: date each version, use a clear revision numbering system (v1, v2, v3), and always confirm in writing which version is the current reference for each sample round.
No Construction Detail on Critical Seams
Impact
The manufacturer defaults to their standard construction. For garments where seam type matters (e.g. raglan sleeve, flatlock seam, bound collar), the result may be structurally or aesthetically different from what was intended.
How to Fix It
Specify seam type for every critical seam: e.g. 'shoulder seam: flatlock', 'side seam: 4-thread overlock, topstitch ¼"', 'hem: twin needle, ¼" hem allowance'.
Single Size Measurement Only (No Graded Table)
Impact
If you only provide measurements for one size, the manufacturer grades the rest using their standard grade rules - which may not match your intended fit across the size curve.
How to Fix It
Provide a full graded measurement table - measurements for every size in your size run. Even if you are only sampling one size initially, the manufacturer needs to know the grade plan.
No Tolerance Column in the Measurement Sheet
Impact
Without tolerances, the manufacturer and QC inspector have no defined acceptable range. Every measurement either passes or fails against the exact number - creating constant disagreement.
How to Fix It
Add a tolerance column to each measurement row. Common garment measurement tolerance: ±1cm for smaller measurements, ±1.5cm for body width, length, and major dimensional measurements.
Relying on Reference Images Instead of Technical Drawings
Impact
A photograph of a reference garment cannot show stitch type, internal construction, seam allowances, or exact proportions. Manufacturers interpret what they see rather than follow what you require.
How to Fix It
Use technical flat sketches (front and back views at minimum) drawn to accurate proportions, with callout lines pointing to key construction details.
Questions
Frequently Asked Questions
How many sample revisions can a bad tech pack cause?
A significantly incomplete tech pack can cause 4 to 7+ sample rounds rather than the typical 2 to 3. Each revision adds 1 to 3 weeks to the pre-production timeline. For brands with seasonal or drop-based deadlines, this can mean missing retail windows entirely.
Does Fenalt help with tech pack development?
Yes. Fenalt's technical team in Dhaka reviews and assists with tech pack creation and POM drafting as part of a managed production engagement.
What is the single worst mistake to make in a tech pack?
Omitting point-of-measure (POM) specifications entirely or providing 3D conceptual renderings without flat dimensions. Pattern makers require 2D measurements to build CAD templates.
How can I check if my tech pack is factory-ready?
Conduct a pre-submission audit: verify that flat vector sketches match POM table descriptions, every trim is listed in the BOM, Pantone codes are specified, and tolerance limits are clearly defined.
Should I include wash care symbols in my tech pack?
Yes. Specifying care tag copy, fiber composition percentages, and ISO wash symbols ensures legal compliance for retail distribution in destination markets (US, UK, EU, AU).
How do version numbers prevent manufacturing errors?
Updating version numbers (e.g. TechPack_Style101_v2.pdf) whenever specs change ensures pattern makers, sample machinists, and QC inspectors all work from the exact same revision standard.
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