Fashion production and garment shipping - DHL Express NZ

In 2024, New Zealand's apparel market is thriving, with revenue reaching US$4.57bn and a projected annual growth rate of 4.07% (CAGR 2024-2028). For fashion designers and brands looking to make their mark in this dynamic industry, turning creative concepts into reality isn't just about design—it's about mastering supply chain management. From sourcing materials to streamlining logistics, every step is crucial. To stand out in this competitive landscape, it’s essential to not only bring your vision to life but also to deliver it efficiently and flawlessly to your customers.

This guide will provide you with a comprehensive overview of the fashion production timeline, logistics considerations, and how partnering with DHL Express can help streamline your operations for success.

1. The fashion production timeline: key stages and challenges

Design and sampling

The design phase marks the beginning of the fashion supply chain, where creativity meets practicality. During this stage, the abstract ideas and inspirations of designers start to take tangible form through sketching and digital design tools. Efficient prototyping and sample creation are critical for fashion brands to quickly translate these concepts into physical samples that accurately reflect the intended look, fit, and feel of the final garment.

As these prototypes take shape, the importance of swift iteration and modification becomes evident, as any delays in the sampling phase can cascade into the entire production schedule. Moreover, this stage is critical for identifying potential production issues, such as fabric shrinkage or stitching flaws, that could cause significant problems later on. 

Material sourcing

Following the design and sampling phase, the next crucial step is sourcing the right materials, a process that significantly impacts both the quality and production timeline of the collection. This phase extends beyond mere aesthetic preferences; it requires a strategic approach that balances quality, cost, and availability. Designers and procurement teams must carefully consider factors like durability, comfort, weight, and seasonal suitability when selecting materials.

Additionally, the reliability of suppliers is paramount, as delays in fabric sourcing can have a cascading effect, potentially disrupting the entire production schedule. This makes it essential for clothing brands to establish strategic partnerships with reputable suppliers who can guarantee consistent quality and timely delivery.

Manufacturing

Once the design is finalised and the necessary materials have been sourced, the manufacturing process can begin. This stage encompasses several critical operations, including cutting the fabric, sewing the pieces together, and finishing the fashion garments with details like buttons and trims. Seamless coordination between the different teams is essential to maintain efficiency and prevent bottlenecks.

Selecting the appropriate production method is also vital, as it directly impacts efficiency and costs. Understanding what the various production approaches are, such as batch production, mass customisation, or just-in-time (JIT) manufacturing, enables designers to choose the best strategy for their specific needs. For example, New Zealand clothing manufacturers offer a diverse range of capabilities, from small-batch production suitable for startups aiming for flexibility to large-scale manufacturing tailored for established brands focusing on mass production.

Quality control

Before garments are ready to be shipped to retailers or directly to consumers, they must undergo a rigorous quality control process. This step is vital to ensuring that the finished products meet both the brand's standards and customer expectations. Quality checks involve a thorough examination of each garment for defects in stitching, fabric quality, colour consistency, and accurate sizing. This stage is particularly important for those looking to start a clothing brand, as making a strong first impression can significantly impact a brand's reputation and customer loyalty.

Furthermore, comprehensive quality control extends to testing the durability and performance of the fashion garments, ensuring they can withstand normal wear and tear. By implementing a robust quality assurance process, brands can identify and rectify any issues before shipping, facilitating smoother logistics. Garments that meet stringent quality standards are less likely to encounter challenges during international shipping from New Zealand to global markets, thereby reducing the risk of delays, returns, and additional costs.

2. Optimising logistics for fashion brands

Warehousing and fulfilment

Efficient inventory management is essential for fashion brands to quickly adapt to changing demand. To achieve this, brands can choose between in-house storage solutions or partnering with third-party logistics (3PL) providers. Many 3PL providers enhance their warehousing capabilities with automated storage and retrieval systems (ASRS), which utilise robotics in logistics to streamline the retrieval and storage of goods. This automation not only speeds up the picking and packing process but also improves accuracy, which can be especially helpful for fashion brands that have a big inventory.

Shipping and customs

Navigating the complexities of international garment shipping is a key challenge for fashion brands. From understanding custom clearance documents to managing duties and taxes, efficient logistics require meticulous planning. Each shipment involves a set of documents, including commercial invoices, certificates of origin, and packing lists, which must be correctly completed to avoid delays. 

For shipments to New Zealand, specific labelling requirements must be met, such as country of origin labelling for footwear and clothing items. Wool products and footwear, in particular, require special labelling to comply with local regulations. Additionally, most tariffs on imported apparel and clothing accessories range from zero to 10%, with rates varying depending on the material and type of product. Similarly, New Zealand fashion companies looking to launch their brand overseas will need to abide by the import country’s customs guidelines to ensure smooth entry and avoid potential delays or penalties.

Returns management

A well-managed returns process is crucial for keeping customers satisfied and loyal in the fashion industry. While flexible return policies can boost sales by encouraging customers to buy, they also require a strong system to handle returns efficiently. Implementing a clear strategy for managing returns, such as offering pre-printed return labels and partnering with reliable logistics providers, can simplify the process for both customers and the business, reducing hassle and ensuring smooth operations.

3. Streamline your fashion logistics with DHL Express

In the dynamic and fast-paced fashion industry, efficiency in production and logistics can make all the difference. From meticulous design and sampling to strategic material sourcing and seamless manufacturing, every step must be optimised to ensure timely delivery and superior product quality. 

For brands looking to enhance their supply chain strategy, DHL Express offers tailored fashion logistics solutions that cater to the unique demands of the industry. With expertise in time-critical shipping, specialised handling of garments, and a vast global network, DHL Express ensures that your collections reach their destinations on time and in perfect condition. Leverage DHL Express’ services to streamline your logistics, expand your reach, and succeed in the global fashion market.

Open a business account with us today and experience seamless logistics support that meets the fast-paced needs of the fashion industry.