Manufacturing Process of a Hand knitted Hat

Below is a hand knitted hat we are discussing about. We will try to explain the manufacturing process of a Hand knitted hat production. The hat measures 55cm round circumference in width and 20cm in height. The hat is made of 100% wool, has a mixed color pompom, includes colorful embroidery and lined with polar fleece, weighting around 70gms.

Once we receive the order on a handknitting hat, we go through following steps

1. Prepare the raw materials
2. Prepare couple of in-house prototype
3. Training to Knitters
4. Prepare Embellishment
5. Weekly Audit
6. Lining
7. Packing
   

1. Prepare the Raw Materials

The first manufacturing process is preparation of main raw materials. The raw materials in this case is wool yarn for knitting & pom and polyester fabric for lining. The yarn is 100% wool that is NM 1/2 of 28 micron wool. The hanks of wool is sourced from local supplier and is sent to dyeing process for the color.

The lining fabric is sourced locally in a roll. They are cut to the size and sewn to the shape.

2. Prepare couple of in-house prototype

Once the yarn is colored & ready, our manufacturing process leads us to make couple of in-house prototype. The prototype serves two purpose. One; its the initial production sample sent to the customer to have final confirmation on production color & other specification. Two; the prototype is used as a reference for knitters group to follow.

3. Training to Knitters

Training is important for all the things we do in our production process. Even if the the knitting is simple & easy, training is a must. Though it is handknitting & the output would not be the same every time, there are many things we can make better by following the tried & tested methods & practices and guideline set while making the prototype.

4. Prepare the Embellishment & Extras

We usually do all the embellishment in house. Doing in house helps us to maintain the quality to maximum extent and these do not take long time as it takes for knitting. In this beanie the the extras is the pompom. The pompom is mix of all the colors used in the hat. Until few years ago, we make pom using a cardboard, now we use clover pompom maker. Pompom maker reduces the wastage and once you start using it, its hard to get back :D.

5. Weekly Audit

We check on with our knitters every week to see the progress and things are going well. This also gives us chance to sort out any issues the knitters are facing and solve it on hand, so that further production would be good.

This process is carried out in two different ways. First one being, one of our staff member visits the knitters group at their location. Another is the knitter visit our office with the goods and get the audit at our facility.

6. Lining

The above hat contains the 100% polyester lining. The polyester lining is sewn by the hand and takes long time than the sewing machine but the finishing looks by hand is much better.
Below is the image of the lining. Full Lining is on the top whereas half lining is at the bottom.

7. Packing & Shipping

Final process in our manufacturing is packing & then shipping. Once the hats is knitted, added pom pom and lined, it is quality checked one last time to make sure everything is as it should be and it is individually packed in LDPE polybags. These packed hats are stacked in large box and will be shipped via cargo/courier.

So there you go, these are the basic steps we follow for production process of handknitted hat at Rochak Handknit Craft. Not every hat is this simple as these days there are lots of embellishment, different knit stitch and different fit & sizes to follow.