Bringing a fashion product from concept to completion is a complex process that requires seamless coordination between design, sourcing, manufacturing, and fulfillment. Without a structured workflow, brands risk delays, miscommunication, quality issues, and increased production costs.

By integrating Product Lifecycle Management (PLM) and Enterprise Resource Planning (ERP) systems, fashion businesses can digitally connect every stage of production, from raw material procurement to final product distribution. This guide will map out the end-to-end fashion supply chain workflow and explain how PLM and ERP solutions like KOBO ensure a smooth, data-driven process from design to delivery.

Understanding the Fashion Supply Chain Workflow

The fashion production process involves multiple interconnected stages, each impacting cost, quality, and efficiency. Below is a step-by-step breakdown of the end-to-end workflow:

1. Design & Concept Development

The first step in the supply chain starts with trend research, mood boards, and initial sketches.

• Fashion designers create concept sketches using software like Adobe Illustrator or CLO3D.

• Technical designers develop tech packs, including fabric details, construction notes, and measurements.

• Product managers set costing and pricing estimates based on material and production costs.

✔How PLM Helps:

• Stores all design assets, color palettes, and tech packs in a centralized system.

• Links designs to material sourcing to ensure feasibility before sampling.

2. Material Sourcing & Procurement

Sourcing the right raw materials—fabrics, trims, labels, and hardware—is crucial for production.

• Brands work with suppliers to request fabric swatches, lab dips, and sample trims.

• Bulk orders are placed based on product specifications.

• Sustainability-conscious brands verify materials for GOTS, OEKO-TEX, and GRS certifications.

  
  

✔How PLM Helps:

• Maintains a digital material library with sourcing details and sustainability certifications.

• Automates purchase order tracking for raw materials.

  
  

✔How ERP Helps:

• Tracks inventory levels for fabrics and trims to prevent material shortages.

• Manages supplier payments and invoicing for bulk orders.

3. Sample Development & Approvals

Before production begins, prototypes and samples must be reviewed for fit, construction, and quality.

• Factories create initial samples based on tech packs.

• Brands conduct fit tests, color-matching, and seam durability inspections.

• Feedback is shared with manufacturers for necessary revisions before final approval.

  
  

✔ How PLM Helps:

• Enables side-by-side comparisons of sample versions, tracking adjustments.

• Provides automated approval workflows for faster sample sign-off.

  
  

✔ How ERP Helps:

• Manages logistics for sample shipments between suppliers, designers, and approval teams.

• Calculates sample cost per unit to ensure profitability.

4. Manufacturing & Production Planning

Once samples are approved, full-scale manufacturing begins. This involves cutting, sewing, printing, dyeing, and finishing.

• Factories receive production-ready tech packs with clear instructions.

• A production calendar is set to track lead times and deadlines.

• Quality control inspections are conducted at different stages to ensure consistency.

✔ How PLM Helps:

• Keeps manufacturers updated with real-time changes to patterns or materials.

• Tracks factory production status to prevent delays.

✔ How ERP Helps:

• Manages capacity planning and workforce allocation at production facilities.

• Automates work-in-progress (WIP) tracking to monitor production efficiency.

5. Quality Control & Compliance Checks

Before products ship, they must pass inspection for defects, compliance, and safety regulations.

• Inspectors check stitching, color consistency, size accuracy, and durability.

• Lab tests are conducted for fabric strength, shrinkage, and chemical content.

• Ethical and environmental compliance audits are performed to verify factory working conditions.

  
  

✔ How PLM Helps:

• Centralizes quality control reports, test results, and defect tracking.

• Ensures that suppliers meet sustainability and compliance standards.

  
  

✔ How ERP Helps:

• Automates returns and replacements for defective goods.

• Generates compliance certificates for regulatory reporting.

6. Warehousing & Inventory Management

Once garments are manufactured, they are stored in distribution centers before reaching retailers or customers.

• Products are tagged and barcoded for inventory tracking.

• Warehouses organize stock by SKU, size, and color for efficient order fulfillment.

• Brands analyze demand forecasts to manage restocking needs.

  
  

✔ How PLM Helps:

• Links production data to inventory levels, preventing overproduction or stockouts.

  
  

✔ How ERP Helps:

• Tracks real-time warehouse inventory and automates stock replenishment.

• Optimizes pick-and-pack operations for faster fulfillment.

7. Distribution & Fulfillment

Finally, finished products are shipped to retail stores, e-commerce platforms, or direct-to-consumer (DTC) customers.

• Orders are processed based on sales channel demands.

• Logistics teams manage shipping, freight, and customs clearance.

• Brands track sell-through rates and customer feedback to inform future collections.

  
  

✔ How PLM Helps:

• Provides sales teams with real-time product availability for accurate order processing.

  
  

✔ How ERP Helps:

• Automates shipping and delivery tracking to ensure on-time fulfillment.

• Generates reports on sales performance and demand forecasting.

  
  

Why PLM & ERP Integration is Essential for Fashion Brands

| Process | PLM Functionality | ERP Functionality |
| --- | --- | --- |
| Design & Development | Tech packs, material sourcing, BOM tracking | N/A |
| Sourcing & Procurement | Supplier compliance tracking | Inventory & purchase order management |
| Sample Approvals | Digital sample review, fit feedback | Sample shipment tracking |
| Production Planning | Production timelines, factory collaboration | Work-in-progress tracking |
| Quality Control | Inspection reports, defect tracking | Automated return management |
| Warehousing & Inventory | Stock level monitoring | Inventory optimization & forecasting |
| Fulfillment & Logistics | Product availability updates | Shipping, invoicing, sales tracking

Conclusion

Managing the fashion supply chain without a digital system is inefficient and prone to delays. By integrating PLM and ERP, brands can:

• Reduce production errors & miscommunication

• Optimize inventory & raw material procurement

• Speed up order fulfillment & distribution

With KOBO PLM and ERP integration, fashion brands can gain end-to-end visibility and create a seamless production workflow from concept to finished goods.

Next Steps:

• Book a demo of KOBO PLM to see how it integrates with ERP.

• Download our End-to-End Supply Chain Optimization Guide.

• Get expert insights on improving production efficiency.