Production Floor — Output Numbers

Manufacturing Capacity.
4 production lines. 120,000 pieces a month.

Four dedicated production lines, 162 sewing stations, 188 floor staff, AQL 2.5 inline QC at five checkpoints. The numbers below are the same ones our planners use when they tell a buyer “yes, by week 5.”

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4 Production lines
162 Sewing stations
188 Floor staff
120k/mo Pieces output
5 QC checkpoints
<1.8% Defect target
Lines A / B / C / D

Four lines. Each one runs one product family, every shift.

We don’t pool sewers across categories. A bra operator stays on bras; a legging operator stays on bottoms. The pattern desk knows which line is loaded and which is mid-changeover when a PO comes in. That’s why the lead times below are realistic, not aspirational.

Line A — tops & bras shop floor
Line A

Tops & Bras (cut-and-sew)

32k–38k Tops / month
Specialises in
Yoga tops, tanks, bras (low/medium-impact), longline crop tops.
Machines
38 sewing stations: high-speed lockstitch, 4-thread overlock, 3-needle flatlock; 4 bartack heads, 2 elastic-attach stations, 1 strap-loop machine.
Floor staff
46 operators, 1 line leader, 2 inline QC inspectors.
Bra-family output
18,000–22,000 pcs / month (the line switches between tops and bras on a planned changeover, never mid-shift).
Lead time
12–18 days for a 500-pc run, 22–28 days for a 2,000-pc run (production only, ex-sampling).

Tops and bras share elastic-attach and strap-loop tooling, which is why we keep them on one line rather than splitting into two. The trade-off is a scheduled changeover every 8–12 days; the alternative was two half-loaded lines.

Line B — bottoms (leggings, biker shorts, joggers) shop floor
Line B

Bottoms (leggings, biker shorts, joggers)

42k–48k Pieces / month
Specialises in
High-rise leggings, biker shorts, jogger pants, flare pants.
Machines
46 sewing stations: heavy-duty flatlock, cover-stitch hem, elastic insertion, gusset-attach; 2 waistband-channel machines, 2 pocket-attach heads.
Floor staff
58 operators, 1 line leader, 2 inline QC inspectors.
Lead time
15–22 days for a 500-pc run, 25–32 days for a 2,000-pc run.
Why largest line
Bottoms are the highest-volume SKU family across our buyer base — roughly 55% of every container we ship.

A buyer reading these numbers should expect the bottom-family schedule to be the tightest of the four lines. We hold the highest single block of peak-season reserve on Line B (see capacity ramp below).

Line C — seamless & bonded shop floor
Line C

Seamless & Bonded (engineered constructions)

18k–24k Pieces / month
Specialises in
Seamless leggings, seamless bras, ribbed seamless sets, bonded-seam tops.
Machines
22 seamless circular knitting machines (24G / 28G gauges), 6 bonded-seam (heat-press) stations, 4 laser-cut stations, 2 ultrasonic welding heads.
Floor staff
28 operators (bonded-seam and laser-cut are skilled trades), 1 line leader, 1 inline QC inspector.
Lead time
18–25 days for a 500-pc run, 30–38 days for a 2,000-pc run. Seamless yarn-to-finish is structurally longer than cut-and-sew.
Why it’s inline
Most yoga factories outsource seamless and bonded work. We keep it under the same roof so the buyer doesn’t pay a sub-contracted markup and so changeover decisions stay on one floor.

Seamless yarn-tension swings drive a higher defect floor than cut-and-sew (we publish that number in the QC section). It’s the only line where the inspector ratio is intentionally 1 : line — bonded-seam defects don’t show up in volume the way flatlock skips do.

Line D — sample & proto atelier
Line D

Sampling, Proto & Short Runs

700–900 Sample sets / month
Specialises in
Pre-production samples, salesman samples, fit-revision rounds, capsule runs ≤ 200 pcs.
Machines
18 mixed stations covering every construction type on lines A–C in miniature, plus a dedicated pattern-and-marker table, a 1-up cutter, and a single-needle hand-finish bench.
Floor staff
14 multi-skilled sample sewers (average tenure 6.4 years), 1 senior patternmaker, 1 sample-coordinator.
Lead time
Confirmed-spec sample in 5–9 working days. Fit-revision rounds in 3–5 working days each.
Why it’s separate
Keeping samples off bulk lines means one buyer’s PP-sample request doesn’t slow another buyer’s bulk shipment.

The floor coordinator has explicit written authority to refuse pulling a senior operator off lines A–C for sample work. It’s the single rule that protects the bulk schedule from sample-request creep.

Reading these numbers and thinking about a brief? Start with the wholesale yoga apparel buyers’ hub with per-SKU MOQ, or jump to custom OEM yoga apparel manufacturing if you have a tech-pack ready.

At-A-Glance Spec Sheet

Print this. The whole floor in one table.

One row per line. The same columns sourcing managers ask for on the first call. If a number isn’t here, it’s because we don’t want to pretend it’s stable across every SKU and season.

Line Family Stations Operators Monthly output Lead — 500 pc Lead — 2,000 pc
A Tops & bras Cut & sew Flatlock 38 46 50,000–60,000 pcs combined 12–18 days 22–28 days
B Bottoms Leggings Shorts Joggers 46 58 42,000–48,000 pcs 15–22 days 25–32 days
C Seamless & bonded Seamless Bonded Laser 22 + 12 28 18,000–24,000 pcs 18–25 days 30–38 days
D Samples & ≤200-pc capsules Proto Fit-rev 18 14 700–900 sample sets 5–9 days (sample) n/a

Sum of mid-range output across A + B + C: 110,000–132,000 pcs / month. We quote 120,000 as the working planning number — every PO sits inside that envelope, with Line D handled as a separate slot.

188 Floor Staff

Specialists, not generalists. We don’t reassign a bonded-seam operator to flatlock.

Yoga apparel has six or seven distinct sewing trades. We staff against that map. A buyer with a bonded-seam SKU is not going to find their sample handed to whoever happened to be free that morning.

Headcount breakdown

146Operators total
6Inline QC inspectors
4Line leaders (one per line)
3 + 2Patternmakers & graders
9Cutters & markers
2Sample coordinator & planner
4In-house mechanics (24h callout)
2Wash-test & fabric-library techs
9Logistics & packing
1Floor manager

Total floor staff: 188. Maintenance covers all machine types on a 24-hour callout cycle — machines don’t sit broken overnight. The pattern desk covers XS–3XL across all 11 SKU families.

Trade depth — where the years live

  • Flatlock & cover-stitch sewers
    Core operators on lines A and B. Hired into trade, promoted within trade.
    5.2yAvg tenure
  • Seamless & bonded operators
    Line C skilled trades — bonded-seam, laser, ultrasonic welding. Hardest hire to backfill.
    7.1yAvg tenure
  • Sample-line operators
    Line D — multi-skilled on purpose. Every one can sew on lines A and B if the schedule demands it.
    6.4yAvg tenure
  • Pattern desk
    3 patternmakers, 38 combined years of yoga-specific drafting. They sign off every first sample.
    12.7yAvg tenure
  • Inline QC inspectors
    All promoted from operator roles. We don’t hire QC inspectors who’ve never sewn.
    4.8yAvg tenure

A buyer reading “average factory tenure 5 years” learns nothing if the 12-year veterans all sew zippers and the bonded-seam line is full of new hires. Trade-level tenure is how a sourcing director can tell whether the line that will actually run their PO has people who know what they’re doing. The companion answer to who buys our fabric and from where is in OEKO-TEX yoga fabric selection and sourcing.

5 Checkpoints · AQL 2.5 · <1.8% Defect Target

Five inspection passes before a piece gets bagged.

One end-of-line check catches defects too late. We inspect five times across the production path, and an inspector has authority to halt a batch — not just flag it.

  1. 01

    Cutting-room audit · pre-sew

    Every layup is checked against the marker for grain alignment, ply count, and shade-block grouping. The reject criteria are written, not verbal: shade drift across a single garment, mismatched grain on the stretch direction, ply count off by more than 0.5%.

    Reject criteria written into the cutting-room SOP — no “judgement call” loopholes.
  2. 02

    Mid-line sewing inspection · in-process

    An inspector pulls a piece off the line every 30 garments per operator. The pulled piece runs through a seam-pull test, a four-way stretch-recovery check, and a stitch-density count. If recovery is under 85%, the batch stops until the line leader signs off on the cause.

    1-in-30 sampling, not 1-in-100 — high enough to catch trends before they become a shipment problem.
  3. 03

    Pre-pack inline check · post-sew, pre-tag

    Garment-by-garment visual: stitch density, label placement, hem evenness, gusset alignment. Anything that fails goes to the repair sub-station, not back into the bag stream. The floor manager’s defect-rate KPI is measured here, at CP3, on the rolling 12-month line.

    This is the number the floor manager is measured on — 1.4–1.7% on A/B, 2.1–2.6% on C.
  4. 04

    Random pull · AQL 2.5 · post-tag

    Statistical sample drawn from the finished batch and checked against the buyer’s tech-pack. Major defects, minor defects, and critical defects counted separately. A batch fails AQL on any single critical defect — no carry-forward, no “we’ll fix it at CP5.”

    AQL 1.0 is available on contract — quoted differently, 3× sample-size, tighter accept-number.
  5. 05

    Final pre-shipment · post-pack

    Carton-level integrity check: counts, labels, polybag seals, master-carton labelling, barcode legibility. Last line before the truck. If a carton fails CP5, the entire master is re-opened — we don’t swap one carton and re-seal.

    One failed carton = master re-open. Predictable for the buyer, painful for the line.

Target at CP3

<1.8%

The number the floor manager is measured on, rolling 12-month line.

Lines A & B actual

1.4–1.7%

Cut-and-sew is where the trade tenure shows up — defect rate stays under target.

Line C actual

2.1–2.6%

Seamless gauge-tension swings are a real defect category. We price for it, not paper over it.

We do not claim a zero-defect factory. Anyone who does is either lying or shipping rework as inventory. A complete view of the upstream paperwork — mill test reports, OEKO-TEX certificates, and audit dossiers — lives on the factory compliance certifications on file page.

50 → 5,000+ Pieces

How fast we ship depends on what size you bring.

There is no single lead time across our factory — different order sizes hit the line differently. The breakdown below is the same planning grid we use internally when a PO arrives.

Bracket 1

Small batch · 50–200 pcs per SKU

8–14 daysProduction lead time

Runs on Line D, or a Line A/B short-cycle slot when Line D is fully booked. Best for first-PO buyers, capsule launches, proof-of-concept runs, and salesman samples.

Routes to: Line D primary
Bracket 2

Medium batch · 200–1,000 pcs per SKU

15–25 daysProduction lead time

Runs on the bulk line for the SKU family (A, B, or C). The most common order size across our buyer base — pricing tiers and lead-time stability both reach their best point in this bracket.

Routes to: A / B / C bulk
Bracket 3

Large batch · 1,000–5,000+ pcs per SKU

25–38 daysProduction lead time

Bulk line, dedicated allocation, may split across two scheduling windows when above 3,000 pcs on a single SKU. Buyers in this bracket get a Gantt-style schedule with milestone dates by week 1.

Routes to: A / B / C dedicated slot

Q3 peak-season buffer

July–September is the heaviest scheduling window across the apparel calendar. We hold 15% of monthly capacity in reserve on lines A and B during Q3 — booked the prior April — to absorb urgent reorders from existing buyers. That reserve isn’t sold to first-time buyers; it’s a stability buffer.

Re-order vs first order

A re-order of a SKU already approved by you — pattern frozen, tech-pack signed off — is 4–6 days faster than a first PO. The PP-sample round and pattern revision are already behind you, so the schedule starts at the cut table.

The Lunar New Year shutdown (typically 7–14 days, dates vary year to year) is published by November 1 each year so buyers can plan pre-shutdown POs around it. Container-mixing logic across SKU families is documented inside the wholesale yoga apparel buyers’ hub with per-SKU MOQ.

What Changes Next Year

2026 plan: a fifth line, two automation upgrades, and one new sampling room.

We publish forward plans because buyers who place 2,000-pc orders need to know whether the factory will be the same shape in 6 months. The plan below was board-approved in February 2026 and is mid-execution.

Q2 2026 — in progress

Line E + Line A automation

  • Line E commissioning. A fifth production line dedicated to outerwear and heavier-weight garments — yoga jackets, fleece-lined hoodies, layered sets. 24 sewing stations planned, fully separate from Line A so cut-and-sew tops aren’t bottlenecked by outerwear changeovers.
  • Spreader-table automation on Line A. Two manual layup tables replaced with an automated spreader. Expected throughput uplift on Line A tops: +8–11%.
Q3 2026 — planned

Line C bonded capacity + 2nd sampling room

  • Bonded-seam capacity doubling on Line C. Six more heat-press stations and two more ultrasonic welding heads added. Driven directly by buyer demand for bonded-seam leggings and seamless sets.
  • Second sampling room adjacent to Line D. Lifts sample throughput from 700–900 sets / month to a target of 1,200–1,400. Standalone, so bulk-line sample requests stop competing with capsule short-runs.
Q4 2026 + Jan 2027 target

Digital cutting + new planning number

  • Digital pattern-cutting upgrade. Cutting room moves to a CAM-driven single-ply cutter for capsule and sample runs (multi-ply manual stays for bulk efficiency).
  • Capacity target. After Line E + automation lands, we lift the planning number from 120,000 → 145,000 pcs / month by January 2027.

What we are explicitly not doing in 2026

We are not opening a second building. Splitting production across two buildings costs us pattern-desk continuity, and that’s not a trade we’re willing to make.

We are not adding a kids-wear line or a swimwear line. Yoga apparel remains the only category on the floor.

The upstream piece — how raw materials and fabric stocks scale with line growth — is documented in how our yoga apparel supply chain is structured.

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