Saturday, February 21, 2009

Problems in Fashion Design & Production – Ideas for Solutions

The following paper was presented by the Organizer of Boston Fashion Industry Meetup, Shirley Willett, and founder of Boston Design Laboratory, February 19, 2009. The paper illustrates her continued commitment to create solutions for the problems and difficulties faced by young design entrepreneurs in the fashion industry today. See more at http://fashion.meetup.com/1/

THE GREATEST CHALLENGE TODAY FOR FASHION DEs IN AMERICA IS AFFORDABLE PRODUCTION.

1. Their production lots are too small to do it overseas – with expensive shipping costs, and paying someone to carefully watch quality control.
2. Production knowledge is not taught anywhere. In the past it was learned by apprentic-ing in the factories. All fashion schools teach 19th century couture for first patterns, which is the process done in the design rooms – making a wider and wider “wall” between de-sign and manufacturing.
3. DEs must increasingly do everything themselves, their own patterns, their own selling and increasingly their own stitching.

MASS PRODUCTION AND “SAMENESS” EQUALS LOW-COST

Frederick Taylor at the turn of the 20th century developed mass production, especially for the auto industry. The basic condition was quantities of sameness. Ford was known to have said: “The customer can have any color they want but it must be black.” Mass production and factories in the apparel industry were developed by Jewish tailors in their patterns created for production of quantities of the same style. They continually developed ways for lower and lower costs.
With the advent of the computer, design rooms disappeared and product development took its place. Everyone designed – sameness, and more sameness. Young DEs can not compete with the way all of them work today, producing one or very few of one style. The solution is to build a large collaboration of designers, whose patterns are all built on one common set of standard (same) pattern templates (Stylometrics). There are many other ways to build some commonalties or sameness as the foundation,(fabric pooling) (systems for cutting and stitching) etc. while uniqueness, customization, and personalization can be done at a higher level. Boston Design Laboratory is committed to research and create ways to achieve affordable production.
This system has not been done yet, but it CAN be done. Only it will take time and the right people – and commitment.


The suede evening gown in the photo was designed in Shirley Willett’s manufacturing business in the 60s, 70s and 80s. She created a totally new production system with sketches on stitcher’s machines with numbers and letters. They made the shell of the gown in 15 minutes. Willett could not sell it that cheap so she made a 60% profit on each. The photo is by Ron Ranere www.positiveimage-boston.com

COSTING CAN HELP SEE THE PROBLEM CLEARLY.
1. Start with a competitive market price of a product – say $200 to the consumer.
2. 50% (often 60%) on average to the retailer. This leaves $100. Selling direct is better, but there is still costs and more labor involved – but reduced by collaboration.
3. To be very general and using my mfg. business as example, make 50% for factory, design, pattern, and other overhead. (Overhead can be reduced substantially here by collaboration.) This leaves $50.
4. If splitting it to $25 for materials, trims and supplies, the materials must be bought wholesale in order to only spend $25 for a garment that the consumer will pay $200 for. This is do-able by collaborating and pooling resources.
5. That leaves only $25 for all labor costs, cutting stitching and pressing. Think of how fast it must be produced to make a quality $200 garment and still get a decent hourly wage. The only way this can be accomplished is in production patterns, and collaborative production systems.




FIRST STEP TOWARD A SOLUTION
A database management system of offers of skills, needs for skills, and project ideas in the Boston fashion industry. Hopefully we can start with “MyZDesign” See www.zweave.com

SECOND STEP: CREATE SELF-EMPLOYED COLLABORATORIES
(SEC)


1. A leader establishes a possible project, and searches database for right people.

2. Each person involved in the project is self-employed & responsible for all their own business processes, and for all decisions. Each has registered on the database what skills they offer and what skills they need.

3. Each buys from others as they need, or forms separate collaborative groups to own a part of the pattern design, production making, promotion or selling of a total project or product.

4. For every transaction a contract is agreed upon and signed dealing with price, time and conditions when paid.

Wednesday, June 11, 2008

A Position Against Copyright Law in Fashion Design





On June 9, in Newport, RI, The Copyright Society of U.S.A., had their annual meeting. I was asked be on the panel of “Copyrighting Couture”, to present my position on the recent legislation going through Congress on a copyrights for fashion design. I presented two plates shown here. What follows is first the 2 minute talk I gave, and second the paper that everyone could download.

1. The battle in copyright law is really between big brand, celebrity designers – most of whom do not do their own designing, and whose profits protect their old hat production – and with tiny (DEs) design entrepreneurs, who have no voice in Washington - and with the copyright law would soon be extinct.

The “Wall Between Design & Manufacturing” is a plate for an NSF grant in 1989 – showing design and manufacturing not communicating. The wall was built by fashion school graduates who didn’t learn how to produce and romantic media promoting that designers didn’t have to know – only celebrity matters. The copyright law in design would make an even bigger schism – and further kill our industry in America.

Innovative production and pattern technologies help reduce prices and raise quality, and are more integral of the true fashion industry – than the look of styles – and doesn’t get, and doesn’t need, government protection. Fashion design is nothing without manufacturing. There are top brand labels copying themselves now, with fast, inexpensive and quality productions - that is the future. AAFA, representing manufacturers, are against the present copyright law proposal.

Promotion to sell my name wasn’t necessary – I sold great products I manufactured myself – such as this evening gown in suede. The stitchers could put the shell together in 15 minutes, and it wouldn’t sell that cheap, so I made 60% profit. How silly to copyright the look. Production is far more important. I designed tools that made buttonholes much higher quality, ten times faster, and the look from the tool helped it sell more. None copied it because I wasn’t media famous.

Today, I am devoted to a new fashion industry for young DEs, for consumers, and to help empower the disadvantaged – giving them my Stylometrics innovative pattern and production systems – for free to copy. Everyone’s a designer – everyone copies – everyone makes money on making – producing at low-cost. Fashion ideas are a dime a dozen.

2-1. Copying has always been an integral and accepted practice in the American fashion industry. (Learned from 60 years experience: apprenticing in 1940s factories, owning 3 corpo-rations (one design &manufacturing), & research in National Science Foundation grants.)
In the 18th century, dolls with French fashions were sent to American dressmakers to copy. In the 19th century fashion magazines printed “patterns” for American dressmakers to copy and cut. At the turn of the 20th century, Jewish tailors in Boston innovated production pattern making, and American fashion apparel, as an industry, was born. These technical designers still copied crea-tivity. Mid-20th century, fashion schools and colleges started – teaching French dressmaking methods, with design creativity, but with no production pattern knowledge. Toward the end of the 20th century, big fashion brand labels hired young designers to exploit their ideas, with fast turnovers, and big name retailers set up their own product development departments to copy, and with most doing offshore production. Young, creative, designer entrepreneurs (DEs) struggle for survival, with no respect from big business, little practical production knowledge, and very little availability to get small production lots made in America anymore.
* A graphic in all of my grants, “The Wall Between Design and Manufacturing”, shows the separation is getting increasingly worse, caused by the lack of communication between the two. Kurt Salmon Associates, 1989, reports, “Merchandising, what manufacturers call designing, is the least-effective function apparel companies perform…a process of creativity and luck. … Re-quirements can change as many as 50 times [from design to making].” The chart, (late 1980s) shows Brand Name Manufacturers as top control. Today that would change with Retailer Brand Names as top control.
* CFDA (Council of Fashion Designers of America) (big names) started the battle for a copy-right law. Their president, Diane Von Furstenberg, says, “My job is to protect the [big name] designers, but the clothing manufacturers want something else.” – validating the bigger wall be-tween design and manufacturing, as well as between big and small designers.
* I fought for these DEs against “big business” as a delegate to the White House Conference on Small Business in 1986, and again as an evaluator of Manufacturing Technology Centers for the National Research Council in 1992.
* Chris Sprigman, in Virginia Law Review, adds: “The global fashion industry produces a huge variety of creative goods without strong IP protection. Copying is rampant as the orthodox ac-count would predict. Yet innovation and investment remain vibrant.”

2-2. A copyright law in fashion design would further smash young design entrepreneurs’ hopes, because every idea would have to be tested against all existing ideas.
* AAFA- American Apparel & Footwear Association (manufacturers), has come out in opposi-tion to the legislation and sent a letter to each member of the House and Senate explaining these concerns. If enacted, these bills would make legitimate companies, and their legitimate designs, vulnerable to a litany of excessive litigation and bogus claims. The inherent subjectivity in both the “substantial similarity” standard for infringement and the “distinguishable variation over prior work” standard for protection would expose footwear and apparel companies, retailers, designers and ultimately the consumer to unneeded costs and uncertainty that could stifle fash-ion design innovation. Moreover, we believe there are practical logistical considerations that would make such a design registry difficult, if not impossible, to operate.
Design (fashion or any industry) must not be separated from its technical design and manu-facturing. Young DEs are the future of America and its free enterprise system. Please, let’s not force every young designer to be controlled by big brands, or by a government that only works for big business and does not understand entrepreneurship and innovation

2-3. Copying great art and design is critical for students to learn what “excellence” is, especially technical and production excellence.
In the Renaissance all learning was by apprenticeship to the great art masters, and is the way fashion apparel, as an industry, started at the end of the 19th century, learning from pattern de-sign masters – and in Boston!! It is the way I approach it today when guiding creative protégés who already have active and successful small business enterprises, but need continual help with technical design and production. My number one protégé, Teresa Crowninshield, is a rising de-sign star in New England. Her cashmere and silk coats and jackets are exquisitely innovative, but she builds each one by copying my fundamental pattern templates, and by copying, for study purposes, other designers’ shapes of myriad parts. In the 1970s on Seventh Ave., New York, pattern makers from different firms would exchange and copy each other’s specific patterns, such as a collar or sleeve, to assure excellent shaping.

2-4. The attention that fashion design innovation is getting is a positive even though I am against a copyright law for it.
What lawyers, academics, and business people – on both sides of the argument, and for all indus-tries - can do is, first, clearly define what design innovation really is; and second, attempt some methodologies for measuring/evaluating design innovation. On the New York Times Freako-nomics Quorum, April 25, “How Can We Measure Innovation?”, John Seely Brown was quoted and names 4 types: “Incremental innovation, cheaper, thinner, faster and, of course, more features. … Architectural innovations, involve a restructuring of the very building blocks of a product family, industry, or infrastructure. …Disruptive innovations, from a societal point of view… . institutional innovations, enable society to function.” Because apparel is 3D, great fashion design through history are architectural innovations. But, like architecture it-self, it cannot be separated from its tangible building and production processes. My very success-ful evening gown in suede in the 1970s is an example of architectural innovation. The production process of setting up images on the machines so the stitchers could make the shell of the gown in 15 minutes was even more innovative that the unique patterning of seams. No one ever copied this gown or any other successful style, because – as I learned – they could not copy my efficient production system. My Stylometrics image language, for which I received 3 NSF grant awards, and today I call “Foundation Pattern Templates”, is an architectural innovation, involving build-ing blocks for fashion apparel designs.
Please let’s learn how to solve our design and business problems without government con-trolling our lives and our businesses.

Tuesday, January 01, 2008

2008 NEWS from BOSTON DESIGN LAB (BDL)



HAPPY NEW 2008!

The purpose for Boston Design Laboratory™ (BDL) is to redesign the fashion industry in Boston, through creative research of new production technologies and new business structures – for consumers to obtain fashions at reasonable cost, and to help DEs (design entrepreneurs) and dressmakers to make a good income – increasingly more difficult in today’s markets. Our research divides the industry into 4 design functions, and forms collaborations of self-employed DEs to develop the new systems. The 4 functions were determined by Shirley Willett, the founder of BDL, in a 2004 paper prepared for Massachusetts Institute of Technology to compare design practices in the fashion apparel industry with other industries, as architecture and automobiles.

In the 21st century every DE must have skills in 4 functions, or collaboratively link to all 4 – because services aren’t available. Each function requires designing – meaning pre-planning.

1. CREATIVE DESIGN is the initial fashion idea with a plan for the functions of: 2) patterns, 3) marketing and 4) production.
When meeting, BDL functions as an informal Design Room, in which we critique each others’ designs, play with fabrics, study ideas for the right consumer, discuss the patterns and any technical problems, and plan the production of the first and repetitions. We are planning a small collaborative collection for 2008, to test BDL’s technology and business ideas. We are also considering a catalog of diverse design ideas at different stages for selling to DEs, dressmakers, and customers.

2. PATTERN DESIGN & ENGINEERING: Patterns are information systems, planned and engineered for production processes, and includes information on specific consumer types.
The Stylometrics Pattern Templates, a foundation pattern making system, was researched in NSF grants and tested by many designers and dressmakers, for making pattern design easier, faster, ready for produc-tion, and more adaptable to custom design. They are ideal for flat 2-D work or for creative draping as on an armature in sculpture. We are building an instruction booklet for selling them.

3. MARKET DESIGN & SELLING is the presentation of fashion products to customers for their acceptance, and must have a pre-designed plan.
For DEs and dressmakers to make a better income, without high prices which will destroy selling in today’s markets, many expensive middling costs must be studied and eliminated. In BDL, we are discuss-ing a possible Fashion Consultants collaboration for selling direct to consumers through trunk shows, home parties, etc. We are also planning some “fitting standards” for mass-produced custom.

4. PRODUCTION DESIGN & ENGINEERING is the plan and management of production processes: cutting, sewing, pressing, trimming - one, many, custom.
Stylometrics Templates are designed for efficient production. BDL is designing a Boutique Production system for collaboratively making quality small lots or custom for less cost. Eventually we hope to collaboratively structure a “Timeshare Factory”, a place for Boutique Production.

Tuesday, November 27, 2007

FASHION as a BUSINESS

Success for Design Entrepreneurs (DEs) in 21st C. Boston


Boston’s Jewish tailors started the apparel industry at the turn of the 20th century by creating production patterns, teaching apprentices, setting up manufacturing shops, and copying creative designs. By mid-century dressmakers in New York and Boston fashion schools began producing creative designers. From the different learning backgrounds, a “wall” arose between creative design rooms and efficient manufacturing and pattern designers – with high costs from poor design management. As manufacturing went offshore in the 1980s, retailers began their own product development, adding CAD systems – and sameness took over.

Young designers who dream of creating “a collection” have presently no path, nor the knowledge, to materialize quality design ideas that can be produced efficiently to make an income. If they could find a pattern maker and a contract shop, the costs would be prohibitive. Boston Design Lab (BDL) evolved to creatively solve these problems through the Stylometrics system (developed in National Science Foundation grants), and by innovating business structures. DEs must be willing to collaborate, working together to create these new systems in Boston. The aim is to eliminate many middling costs from designer to consumer, without losing quality and uniqueness, and to set up IT (Information Technologies) to solve product lifecycle problems at POD (Point of design).

Pattern Templates are part of the Stylometrics system, upon which DEs develop creative design ideas (by draping or flat work), to result in a pattern that is ready for efficient production. Sameness in product and processes give speed, efficiency and low-cost in production. The Templates are a foundation of sameness for creative 2-D art or 3-D fashion sculpture, and works to eliminate many costly repetitions

Some innovative business structures in BDL are:
“Boutique Production”
; a
“Timeshare Factory”
; training fashion consultants to work with DEs for selling direct to consumers in trunk shows, expos, etc.; software, such as “Self AWear™” for collecting consumer preferences in databases; critiques for saleability to myriad market demographics; linking with a sewing professionals association, for making custom or small lots.

Tuesday, November 20, 2007

BOSTON DESIGN LABORATORY™ Some information








The purpose for Boston Design Laboratory™ (BDL) is to redesign the fashion industry in Bos-ton through creative research of new production technologies and new business structures – in order that fashion design entrepreneurs and dressmakers can make a good income – increasingly more difficult in today’s markets. Our approach encompasses all aspects of the industry, collaborations in the ways the self-employed work together in creating solutions to problems. There are four divisions, determined by Shirley Willett, the founder, in a 2004 paper prepared for a Massachusetts Institute of Technology workshop to explain the future design of the fashion apparel industry. Information is collected in databases and other technologies for designer quality and efficiency at the Point of Design (POD-IT)

1) Creativity, Research & Resources.
Problem: Much creativity in the fashion apparel industry has been lost with the mechanization of CAD/CAM technology, which has opened up extensive copying and repetitions.
Future:. All BDL designers and dressmakers start with the Stylometrics Pattern Templates, researched by Shirley Willett in a series of National Science Foundation grants, for achieving more beautiful, creative shaping, quality fitting, and efficient production of one-of-a-kinds, small or big production lots. The system is highly efficient for development of creative ideas and can reduce necessity of copying and sameness.


2) Pattern Design & Engineering.

Problem: Commodity apparel is completely mechanized in CAD pattern systems for low-costs in design and production – while high fashion is too random and expensive, poor time management from design to market. Unfortunately, there is nothing in between.
Future: The Stylometrics system is structured so that while designing and making the first sample (prototype), the pattern is also ready for production. The Templates are ideal for easy manipulation of flat 2-D work, or for creative draping as on an armature in sculpture.

3) Production Engineering.
Problem: Sameness in product and processes give speed, efficiency and low-cost, but results in boring styles. Manufacturing in America of high fashion design is extremely limited and costly and non-existent for very unique ideas, small lots, one-of-a-kinds, or custom.
Future: It is integral to BDL’s mission to solve these problems through technical innovations linked to the Stylometrics system, which has a foundation of sameness upon which to build great creativity. BDL is working with the Professional Association of Custom Clothiers (PAAC) on “mass-produced custom”, and is proposing a “Boutique Production” concept.

4) Marketing, Selling & Customers.
Problem: Too many middling costs, and distortion of consumer desires from the distance between designers and consumers.
Future: Trunk shows, direct sales, and creative, collaborative marketing are integral parts of our research. Our dream is to make the customers an active part of the fashion industry, with a software program, “Self A-wear™” which will collect consumer desires, and a “Willett Design Room” (WDR) that can maintain the unique selling relationship.

Emma left a comment on the last post:
what are the styleometrics pattern templates? I am designing and making a modern wedding dress and was needing some help with how to make a pattern


Some of your question is answered above, but I realize not in any detail. If you live in the New England area, please contact me, and I can suggest some ways to help you with patterns. You can also read my website at http://www.shirleywillett.com You can also join the Boston Fashion Industry Meetup. Click http://fashion.meetup.com/1/

Sunday, October 28, 2007

Draping a Dress from Stylometrics Pattern Template





The blue and white silk crepe dress is on me when I received a "Boston Fashion Week Ladder Award" sponsored by the Fashion Group International in September. It was for all my work to help young fashion entrepreneurs up the "ladder". The photo was tajen when I received a unique bouquet of roses from my fashion protégés at our Boston Design Lab fashion show.

In a post on 12.26.2006, "Drape Dress" I showed the design for this dress, and the AB-1 Empire Template on which the dress was draped. I added the big bow. All the darts and the empire line was transformed into draping, which is something I love to do. By draping from a Template the dress maintains a "standard" of sizing and shaping,the lack of which is a significant problem that consumers face, especially with haute couture from around the world.

I love comments and questions. If you have any about this process I will reply.

Sunday, October 21, 2007

Boston Design Lab Fashion Show




First, I apologize for such a long time since my last post. But I am now going to be doing many posts, lots of photos from my fashion show, "Boston Design Lab" at the Hotel Commonwealth during Boston Fashion Week in September. These are two photos by Ron Ranere, Positive Image. You can see many more on his web site,http://www.positiveimage-boston.com/bdlweb/index.htm
There are also more photos on BostonFashion.com at http://www.bostonfashion.com/directory/bostondesignlab.html

I will be getting up more this week, and will work out the problem of leaving comments. Thanks for your patience.