Custom Sleepwear & Nightwear from PJS Factory — A Factory’s Detailed Guide

Introduction

As a factory partner, PJS Factory approaches every custom sleepwear program with the same priorities: repeatable quality, predictable lead times, cost transparency, and compliance. This article explains our end-to-end OEM and ODM workflows in technical detail – what we expect from brands and importers, what we do at each step, how decisions affect cost and timing, and how to avoid the common pitfalls that slow product launches.

Whether you’re launching a small capsule (low MOQ) or scaling to full-season assortments, this guide gives you the factory-side playbook so you can plan accurately and move quickly.

Executive summary (what the factory needs up front)

To get a smooth production run you must provide, as early as possible:

Clear tech packs (for ODM) or clearly chosen catalog SKUs (for OEM).
Fabric and trim references (swatches or supplier names).
Target retail price or target landed cost (so we can recommend construction/fabric tradeoffs).
Desired delivery window and preferred Incoterm (EXW/FOB/DDP).
Contact person for approvals and timely feedback.

If any of those items are missing, expect additional sample rounds, delays in material procurement, and extra cost.

OEM: Detailed factory-level process (catalog → your brand)

1. Initial contact & brief

When you contact us, tell us:

Target market and retail positioning (luxury, mid-market, value).
Expected annual volume and first-order qty.
Any market-specific tests or labeling requirements (e.g., textile labelling laws, flammability).
This input lets us propose catalog options and realistic lead times.

2. Catalog delivery (what we include)

Our catalog is not just pictures. It includes:

Style code and technical flats.
Fabric specification (composition, GSM, width, supplier reference).
Suggested colorways and Pantone references.
Standard size chart and grading rules.
FOB/EXW price bands and MOQ for each SKU.
Typical lead time and packaging options.

3. Selecting a design & requested modifications

You may pick a catalog style and request changes. From the factory view:

Cosmetic tweaks (colorway, thread color, label) — quick and low-cost.
Structural changes (nursing openings, different pocket placement, new closure) — require pattern adjustment and a sample fee.
Any change that alters BOM (bill of materials) — will change the lead time and price.

4. Order detail alignment (BOM, pack spec, labeling)

Before quoting we lock down:

Exact fabric (supplier + dye lot window), trims, elastic types, and hardware specs.
Hangtag artwork, care label copy, and placement.
Packing rules: units per inner pack, polybag spec, carton dimensions.
This prevents costly mid-run changes.

5. Quotation & commercial terms

Factory quotes separate cost drivers:

Material cost (fabric + trims consumption).
Labor cost (stitching, finishing).
Overheads (setup, pattern, grading).
One-off fees (pattern, tooling, sample).
We also present freight estimate options (FOB vs CIF vs DDP) so you can compute landed cost.

6. PPS (Pre-Production Sample / Golden Sample)

From a factory perspective the PPS is the production baseline:

Made in production fabric and with final trims.
Confirms print registration, stitch types, seam allowance, labels, and measurements.
Any change after PPS typically leads to a re-PPS and additional charge.

7. Contract, PI issuance & payment milestones

We issue a Proforma Invoice (PI) with:

Payment schedule (commonly 30–50% deposit, balance before shipment or per milestones).
Lead-time calendar and penalties if negotiated.
Agreed AQL and QC procedures.

8. Material procurement and pre-production checks

Once deposit is received we:

Order fabric and trims (we track delivery ETA and lot numbers).
Pre-inspect incoming fabric (GSM, width, dye lot, visual defects).
Delays in raw material delivery are the largest cause of production slippage.

9. Cutting, sewing and in-line control

Key factory controls:

Marker planning to optimize fabric yield.
First-cut and audit to validate pattern accuracy.
In-line inspection points (post-sewing, post-trim) to catch defects early.

10. Final inspection & QC report

We run AQL-based inspections and provide:

Measurement charts vs spec for sample of garment pieces.
Photos of critical defects and corrective actions taken.
A pass/fail decision according to agreed thresholds (major/minor defect AQL).

11. Packing, customs docs & shipment

We prepare:

Packing lists, weight & carton dimensions, and required certificates.
Export declarations and any requested compliance docs.
You can select shipping method and Incoterm at this stage.

12. Receiving & claims handling

We provide full packing and QC documentation to simplify your receiving process and speed up any claims for transit damage or QC rejects.

ODM: Detailed factory-level process (your design → factory production)

1. Contact & tech pack intake (what we need)

A complete tech pack must include:

Flat sketches (front/back/side), construction notes, and seam allowances.
Detailed measurement chart with tolerances.
Fabric composition and supplier (or swatch).
Trim specs (zippers, buttons, elastic width, thread type).
Artwork files in vector format (AI/PDF) with color separations and Pantone numbers.
Quality tech packs reduce sample loops dramatically.

2. Quotation & cost drivers for new designs

ODM quotes include:

Pattern & grading fees (one-off).
Prototype/sample charges (first-fit and fit corrections).
Fabric development costs if using custom weaves/dyes.
We explain cost drivers and suggest alternatives to align with target landed cost.

3. Swatches, prototypes & fit iterations

Typical sequence:

Send fabric swatches to confirm hand and color.
Produce toile or first-fit sample in cheaper fabric if needed.
Produce final sample in production fabric for fit approval.

4. Full-size sample (PPS) and pre-production checks

Once you approve the full-size sample we:

Lock grading rules and BOM.
Create the production SOP (stitch types, machine settings, operation sequence) to ensure repeatability.

5. Production, inline QA and yield optimization

We focus on:

Yield tracking (defects per 1000 units) and root-cause actions.
Operator training for specialized operations (embroidery, satin finishing).
Productivity planning to meet the contracted ship date.

6. Lab testing & compliance for target markets

Depending on destination we perform or coordinate:

Shrinkage tests, colorfastness (wash & rub), pilling, seam strength.
RSL testing for prohibited chemicals (when requested).
Market-specific tests (children’s sleepwear flammability, if relevant).
We share lab certificates with shipment docs.

7. Final inspection, packaging & shipment

We perform final AQL checks and package per your retail or e-commerce spec, then handle export paperwork as agreed.

Quality control, certifications & compliance (factory perspective)

From our side, we maintain structured QA & compliance:

Incoming fabric QC (report GSM, defects, dye lot).
In-line QC checkpoints and a final AQL inspection. Typical AQL settings we work with: Major 2.5 / Minor 4.0 / Critical 0.65 (adjustable by agreement).
Certifications we can support: ISO 9001 processes, social audits (BSCI / Sedex / WRAP), and textile standards (OEKO-TEX / GOTS) — we can provide audit reports and traceability documents.

Note: Always request copies of certificates and recent audit summaries and verify scopes — e.g., OEKO-TEX covers restricted substances, GOTS covers organic fiber processing chain.

Sampling strategy & timelines (best practice)

Initial sample / first-fit: 5–10 working days (pattern + basic fit).
PPS / Golden sample: 7–14 working days (production fabric & trims).
Bulk production: Typically 30–75 days after PPS approval depending on quantity, fabric lead time, and seasonal backlog.
Faster timelines require pre-arranged material lead times and confirmed capacity.

Cost breakdown & landed cost considerations

A responsible factory quote shows:

Fabric cost per garment (fabric consumption × fabric price).
Trims cost (labels, elastics, buttons).
Labor & overhead per unit.
Sampling, pattern & grading fees.
QC & inspection fees.
Freight estimate and duty assumptions (so you can calculate true landed cost).

Ask suppliers to provide a sample landed-cost worksheet so you can compare offers fairly.

Packaging & logistics (retail vs D2C)

For retail: folded on hangers, swing tags, size stickers, master carton specs (units per carton), polybag + barcode.
For D2C: choose e-commerce packaging (fold method, branded polybag, return label space) to reduce returns and improve unboxing experience.
We can produce custom cartons and apply UPC/barcodes on request.

Risk management & dispute resolution (factory perspective)

Common risks: material shortages, dye lot mismatch, late buyer approvals, shipping delays. Mitigation actions:

Buy critical fabric early with buyer deposit.
Use color-seal photos and lab tests for color-sensitive items.
Milestone payments and holdback clauses for final quality assurance.
Agreed arbitration or dispute resolution clause in the contract.

KPIs we measure and report to clients

On-time delivery rate (target >95%).
Defect rate at shipment (target <2% major defects).
First pass yield (percent of units passing in-line QC).
Sample turnaround time (days per sample round).
We share weekly production dashboards on large programs.

Practical checklist for brands — factory essentials

Provide tech pack or choose catalog SKU.
Confirm fabric supplier or request swatches.
Approve PPS before bulk.
Agree payment milestones and Incoterm.
Confirm packing, barcode, and shipping detail.
Request inspection report and lab certificates.
Keep a 5–10% buffer for rework and returns when launching new SKU.

Conclusion — what PJS Factory expects from you (and what we will deliver)

From the factory perspective, clarity and timeliness on technical specs, approvals, and payments are the levers that control quality, cost, and lead time. Give us precise tech packs or catalog choices, clear approval timelines, and realistic lead-time expectations — and we will deliver repeatable production, thorough QC, and transparent communication. That partnership model is how we scale sleepwear lines reliably.

Frequently Asked Questions (factory perspective)

Q1 — What is the difference between a sample, PPS and golden sample?
A: The sample (first-fit) checks pattern and basic silhouette. PPS (pre-production sample or golden sample) is made from production fabric and trims; it becomes the production benchmark. Any changes after PPS generally require a re-PPS.

Q2 — What tech pack details are non-negotiable?
A: Flat sketches, full measurement chart with tolerances, BOM with fabric supplier or swatch, artwork vectors (AI/PDF), and precise label/care instructions.

Q3 — How do we avoid dye lot or color mismatch?
A: Approve fabric swatches with Pantone references, order all fabric for an order in one dye lot, and request lab colorfastness reports if needed.

Q4 — What quality standard do you use?
A: We operate with AQL sampling; typical targets are Major 2.5 / Minor 4.0 / Critical 0.65. For critical programs we recommend third-party inspection and lab testing.

Q5 — How can I reduce sample loops and speed to market?
A: Invest in a complete tech pack, clearly define tolerances, approve swatches promptly, and agree to a strict sample approval window to avoid delays.