How to formulate a BOM list for T-shirt fabrics?

Struggling with inconsistent quality, production delays, or cost overruns in your T-shirt production? Many start-ups underestimate the importance of a clear and standardized Bill of Materials¹ (BOM), leading to avoidable mistakes and confusion. How exactly can you structure an accurate and reliable BOM for your T-shirt fabrics and accessories?

A comprehensive clothing BOM clearly outlines main materials (fabric details), auxiliary materials² (collars, cuffs, labels, packaging), and precise specifications (composition, GSM, yarn count, dyeing methods). This ensures standardized production, consistent quality, precise costing, and effective supplier management, significantly reducing errors and waste.

At Modaknits, creating clear BOMs was fundamental to our growth. Here’s my practical guide to structuring your T-shirt BOM clearly and effectively.

What is a clothing BOM list? Why must T-shirt products be standardized?

A BOM (Bill of Materials) clearly documents every material needed to manufacture a product. Standardizing your T-shirt BOM ensures consistent quality, controlled production costs, and reduces misunderstandings or errors during production.

A clothing BOM lists all fabrics, accessories, and processing details required for production. Without a standardized BOM³, T-shirt brands face risks like inconsistent samples, production errors, increased costs, and delivery delays.

What is the core role of BOM (Bill of Materials) in the clothing industry?

The BOM clearly provides a structured, detailed inventory of materials required for each garment. It ensures accurate cost calculations, stable quality, efficient procurement, and streamlined production processes.

Core Roles of BOM	Benefit
Standardization of materials	Consistent product quality
Cost control and accurate budgeting	Precise cost estimation
Efficient supplier management	Clear material sourcing
Production accuracy	Reduced errors and waste

What risks will there be in sampling, production and cost without a standard BOM?

Stage	Potential Risk
Sampling	Inconsistent quality, multiple re-samples
Production	Errors, delays, miscommunication
Cost Control	Budget overruns, hidden material costs

Clear, standardized BOM prevents these costly problems effectively.

What are the basic components of the T-shirt BOM list?

An accurate T-shirt BOM clearly documents main fabrics, auxiliary materials, processing techniques, and quality standards to ensure streamlined production and accurate cost control.

Key BOM components include main fabric details (composition, GSM, yarn count), auxiliary materials (collars, cuffs, labels), processing methods, supplier info, and quality specifications.

What key parameters should be marked for the main material (Body Fabric)?

Parameter	Example
Fabric Composition	100% Combed Cotton
GSM (Gram weight)	180g/m²
Yarn Count	32S single jersey
Weave Structure	Plain knit
Dyeing/Finishing	Reactive dye, pre-shrink
Color Specification	Pantone TPX 19-4005

Clearly specifying these parameters ensures consistency across batches.

How to systematically classify auxiliary materials (collars, cuffs, trademarks, etc.)? Is it necessary?

Systematic classification is necessary to ensure clarity and precision. Classify auxiliary materials clearly by type and function:

• Ribbing (collar/cuff fabrics)
• Labels (brand, size, washing care)
• Hangtags (branding, pricing information)
• Threads and stitching (specify color, thickness)
• Packaging materials (polybag, carton details)

Clear classification ensures consistent quality and simplifies procurement.

How to fill in fabric information in a standardized manner? Standardized expression from gram weight, composition to process

Accurate fabric descriptions are crucial. Standardized filling clearly ensures consistent interpretation by suppliers, production teams, and quality inspectors.

Fabric information in BOM should clearly include GSM, yarn count, fabric composition, weave structure, dyeing methods, and finishing processes.

How to write gram weight GSM, yarn count, organizational structure, and dyeing and finishing methods into the BOM?

Parameter	Standardized Example
GSM (Weight)	180g/m²
Yarn Count	32S single jersey
Fabric Structure	Plain knit (single jersey)
Dyeing Method	Reactive dyeing (Colorfast Grade 4+)
Finishing Method	Mercerized, Pre-shrink treatment

Consistent formatting avoids confusion and production errors.

Should fabric color, batch number, and supplier information also be included in the standard BOM?

Absolutely. Including color codes (Pantone number), fabric batch number, and supplier details ensures traceability, accurate reproduction, and efficient issue resolution.

Information	Importance
Fabric Color (Pantone)	Accurate color reproduction
Batch Number	Quality control, traceability
Supplier Information	Efficient sourcing, accountability

How can a startup brand formulate a BOM template suitable for sampling and mass production?

Startup brands should develop scalable BOM templates, clearly suitable for both sampling and large-scale production.

Initially use Excel templates for flexibility and easy updates. Transition to ERP systems as your business scales for better efficiency and data management. Adjust material details slightly based on production scale, clearly marking standards for each stage.

Can Excel or ERP system be used to manage BOM? What formats are recommended?

Management Tool	Suitability	Recommended For
Excel	Flexible, easy editing	Early stages, small runs
ERP System	Efficient, automated	Mass production, scaling

Excel is practical initially; ERP is ideal for growth.

Small batch vs. mass production, what adjustments should be made to the BOM content in the two stages?

Production Scale	BOM Adjustment Recommendation
Small batch	Detailed notes, flexible options
Mass production	Precise, standardized, simplified

Clear standardization reduces error as scale grows.

In addition to the main material, how should the common auxiliary materials of T-shirts be filled in and the quality controlled?

Auxiliary materials must also be clearly detailed in the BOM to avoid overlooked issues affecting brand quality.

Clearly list each auxiliary material separately, with detailed specifications such as material, dimensions, color, and supplier. Clearly defined quality standards help maintain overall brand integrity.

Are hangtags, washing labels, stitches, packaging bags… all considered part of the BOM?

Yes. Every item required for a complete product, including hangtags, washing labels, stitches, and packaging materials, should be clearly included and detailed in your BOM.

Auxiliary Material	Include in BOM?	Reason
Hangtags	Yes	Branding, pricing info
Washing labels	Yes	Essential care information
Stitches & Threads	Yes	Impacts product durability & style
Packaging bags	Yes	Brand image, protection, consumer perception

How to set the quality standards for auxiliary materials to avoid losing the big picture due to small details and affecting the brand sense?

Clearly specify quality requirements such as material type, color fastness, strength, dimensions, printing accuracy, and overall appearance for each auxiliary material.

Example for hangtags:

• Material: 300gsm coated art paper
• Printing: Double-sided full-color, matte finish
• Dimensions: 5cm x 9cm
• Punch hole diameter: 4mm (metal eyelet recommended)

Clear standards avoid quality inconsistencies and strengthen brand premium positioning.

Conclusion

Accurate and standardized BOM formulation clearly ensures consistent quality, efficient production, and controlled costs for your T-shirt brand. Clearly detail main fabrics, auxiliary materials, processing methods, and quality standards. Adopting scalable formats from Excel to ERP systems prepares your brand effectively for growth, ensuring long-term reliability and success.

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