5 Bill of Material Strategies for Apparel
A great design starts with a sketch. A great product starts with a Bill of Materials (BOM). In the fashion world, the BOM is your recipe. It tells the factory exactly what to buy and how much.
Many brands lose money because of small errors in their tech packs. These errors lead to high costs and late shipments. Lifecycle PLM helps brands fix these issues early. We focus on building data that works for your team and your factory.
Here are five strategies to make your BOM professional and production-ready.
1. Plan for Fabric Waste
You cannot just order the exact amount of fabric you need. Real life does not work that way. Factories face many issues during production. Machines may snag the cloth. A roll of fabric might have holes or stains. Fabric also shrinks when you press it.
Professional designers use a wastage factor. This is a small extra amount added to the total yardage. Most brands add $3\%$ to $5\%$ extra.
Why this works:
It covers cutting room errors.
It accounts for fabric flaws.
It ensures you have enough cloth to finish the full order.
Without this buffer, you might end up ten shirts short. Buying more fabric at the last minute is expensive. It also delays your ship date. Lifecycle PLM makes it easy to track these yields across your whole line.
2. List Approved Material Subs
Supply chains are messy. A factory might run out of the specific zipper you want. A boat could get stuck at sea. If your BOM only lists one option, production stops.
Smart brands list "Approved Alts" for small items. These are secondary choices for things like pocket bags or lining. You do not need a backup for your main fabric. You do need one for the parts that do not change the look of the garment.
Why this works:
It keeps the sewing lines moving.
It gives the factory power to solve problems fast.
It prevents delays caused by minor trim shortages.
Tell your factory which trims they can swap. This builds trust and keeps your schedule on track.
3. Use Global Color Standards
Colors look different on every screen. "Navy" to one person looks like "Charcoal" to another. Even factory lights can change how a color looks. This leads to "color drift." This is when your bulk goods do not match your sample.
Your BOM should list a Pantone TCX number for every color. This is a global code that everyone uses. You should also name the light source for checks. Most brands use a standard "D65" light box.
Why this works:
It makes color matching exact.
It removes guesswork for the dye house.
Your clothes will look the same in every store.
Using a clear standard protects your brand. It ensures your vision stays the same from the lab dip to the shelf.
4. Track Lead Times and MOQs
A BOM is more than a list of parts. It is a tool for your timeline. Every fabric and button has a Minimum Order Quantity (MOQ). They also have a lead time. Some custom buttons take eight weeks to make.
If you do not track these, you will miss your launch. List these details directly in your BOM. This helps your team see "long-lead items" early.
Why this works:
You can buy slow items before you finish the full design.
It helps you manage your cash flow.
It stops panic buys at the end of the season.
Lifecycle PLM helps you see these dates in one placed. You will know exactly when to place every order.
5. Set Clear Performance Rules
A fabric might look good but perform poorly. It might pill after one wash. It might bleed color onto other clothes. You must list your technical needs in the BOM.
Specify the weight in grams per square meter (GSM). List the pilling resistance level you expect. Mention colorfastness rules. These are your quality benchmarks.
Why this works:
It acts as a quality contract with the factory.
It gives you a reason to ask for a refund if things go wrong.
It ensures the customer gets a product that lasts.
If the fabric fails a test, the BOM is your proof. It shows what you asked for and what the factory agreed to make.
Why Better BOMs Matter
The fashion industry moves fast. Brands that stay organized win. A detailed BOM reduces the back-and-forth emails with your factory. It makes costing more accurate. Most importantly, it keeps your "hidden costs" low.
When your data is clean, your business grows. Lifecycle PLM helps you master these five moves. We provide the tools to build better tech packs and stronger supply chains.
Strategy | Key Benefit |
Wastage Factors | Stops fabric shortages |
Approved Alts | Prevents production stops |
Pantone Codes | Keeps colors consistent |
MOQ & Lead Times | Secures the timeline |
Testing Standards | Ensures high quality |
Use Better Data Today
Many designers feel overwhelmed by spreadsheets. You do not have to do it alone. Moving your BOM to a PLM system changes everything. It turns a static list into a live tool.
Your team can see updates in real time. Your factory gets clear instructions. Errors drop. Profits rise. This is the goal of every professional brand.
Focus on these five areas in your next tech pack. You will see fewer mistakes and better products. Your factory will thank you. Your customers will notice the quality.
Ready to see how these strategies work in action? Book a quick demo with Lifecycle PLM today.
Conclusion
Building a professional BOM is the best way to protect your profit. These five moves turn a simple list into a strong production plan. You will avoid late shipments and costly fabric mistakes. Clear data helps your factory work faster and with fewer errors. It gives your team the confidence to scale your brand without the usual stress. Lifecycle PLM makes it easy to manage these details in one place. You can track waste, color codes, and lead times with ease. This organization helps you stay on schedule every season. Good data is the foundation of a successful clothing line. Take control of your production today and watch your business grow.
Sam Lillicrap
CEO OF LIFECYCLE FASHION PLM
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