In the fast-paced world of fashion, top brands are streamlining product creation to reduce lead times, minimize costs, and increase agility. Traditional design-to-production processes are often slow, inefficient, and error-prone, leading to delays, wasted materials, and lost revenue opportunities.

So how do top-performing brands accelerate product development without compromising quality? The answer lies in technology-driven workflows, digital collaboration tools, and strategic supplier partnerships.

This article explores how leading fashion brands optimize product creation using PLM (Product Lifecycle Management), AI-driven automation, and seamless supply chain integration.

Step 1: Digitizing the Product Development Workflow

Many brands still rely on manual spreadsheets, disconnected design files, and email approvals—a slow and outdated approach. Top brands have digitized product creation using PLM software, eliminating bottlenecks and improving collaboration.

Key Benefits of PLM for Product Development

• Centralized Design Files & Tech Packs – Ensures everyone works with up-to-date versions.

• Automated Sample Approvals – Reduces back-and-forth delays with digital approvals.

• Real-Time Material & Cost Tracking – Prevents last-minute budgeting surprises.

• Supplier Integration – Streamlines communication between designers and manufacturers.

  
  

✔ How PLM Helps:

• Stores digital sketches, mood boards, and fabric specifications in one platform.

• Tracks sample revisions, reducing unnecessary prototypes and costs.

Example: A leading sportswear brand cut product development time by 30% after switching from email-based communication to real-time PLM tracking.

Step 2: Accelerating Sampling & Reducing Waste

Traditional sampling involves multiple rounds of physical prototypes, leading to high costs and fabric waste. Innovative brands are now adopting digital solutions to speed up approvals while being more sustainable.

How Top Brands Optimize Sampling

• 3D Virtual Sampling & Digital Prototyping – Brands like Nike and Burberry use 3D modeling to test designs without making physical samples.

• AI-Powered Fit Adjustments – Reduces manual grading and speeds up pattern modifications.

• Automated Fabric Testing – Ensures materials meet stretch, durability, and color fastness standards before bulk production.

✔ How PLM Helps:

• Integrates with 3D design software (CLO3D, Optitex) to reduce physical sampling.

• Stores fit feedback and revisions in one place for seamless adjustments.

Example: A luxury brand cut sample production costs by 40% after integrating digital sampling into their PLM workflow.

Step 3: Automating Supply Chain & Material Sourcing

Many brands struggle with unreliable suppliers, long lead times, and material shortages. The most efficient companies streamline sourcing by:

• Using AI for Predictive Demand Planning – Helps brands forecast fabric needs and reduce waste.

• Automating Purchase Orders via ERP Integration – Prevents delays in material procurement.

• Building Sustainable Supplier Networks – Ensures ethical sourcing and compliance with standards like GOTS and OEKO-TEX.

  
  

✔ How ERP Helps:

• Tracks supplier lead times and pricing data for smarter sourcing decisions.

• Automates purchase orders and inventory management to prevent stockouts.

Example: A global denim brand reduced fabric waste by 25% after integrating AI-powered inventory forecasting with their ERP system.

Step 4: Optimizing Production with Real-Time Data

Efficient production management is crucial for preventing delays, overproduction, and quality control issues. Top brands use real-time production tracking and automated workflow tools to stay ahead.

Key Tactics for Smarter Production

• Real-Time Factory Communication – Brands use PLM-integrated supplier portals for instant production updates.

• Smart Manufacturing & RFID Tracking – AI-driven factories optimize fabric cutting, dyeing, and assembly.

• Automated Quality Control Inspections – Digitized QC checklists reduce errors and defects before shipping.

  
  

✔ How ERP Helps:

• Tracks real-time production status to prevent delays.

• Automates defect logging and supplier performance analysis.

Example: A fast-fashion retailer increased on-time deliveries by 35% after implementing RFID-tracked manufacturing workflows.

Step 5: Reducing Time-to-Market with Agile Workflows

To stay competitive, fashion brands must shorten design-to-delivery cycles. Leading companies achieve this by:

✔ Implementing Agile Design Sprints – Launching mini-collections faster instead of seasonal drops.
✔ Pre-Order & On-Demand Production – Reducing overproduction while testing market demand.
✔ Data-Driven Product Decisions – Using sales analytics to predict bestsellers before bulk production.

✔ How CRM Helps:

• Tracks customer feedback and purchase patterns to refine future collections.

✔ How ERP Helps:

• Ensures real-time stock updates to prevent sellouts or deadstock.

Example: A DTC fashion label reduced time-to-market by 40% by shifting from seasonal drops to rolling product launches.

Key Takeaways: How to Streamline Product Creation

| Process | How PLM Helps | How ERP Helps |
| --- | --- | --- |
| Digital Product Development | Centralizes sketches, tech packs, and revisions | Tracks material costs and supply chain lead times |
| Faster Sampling & Prototyping | Uses 3D digital sampling & AI-powered fit adjustments | Ensures pre-production testing meets QC standards |
| Smart Supply Chain Sourcing | Stores supplier details and certifications | Automates purchase orders and inventory tracking |
| Real-Time Production Optimization | Connects manufacturers for live updates | Tracks production status & delivery schedules |
| Agile Time-to-Market Strategies | Manages pre-orders & on-demand production planning | Aligns inventory with real-time customer demand

Conclusion

Top fashion brands are streamlining product creation by adopting PLM, ERP, and automation technologies. From faster sampling and AI-powered sourcing to real-time production tracking, these strategies help brands reduce costs, minimize waste, and accelerate time-to-market.

Next Steps:

• Book a KOBO PLM demo to optimize product development.

• Download our Fashion Production Optimization Guide.

• Learn how ERP can streamline sourcing & inventory management.