What Causes Delays in Apparel Production — and How to Avoid Them

In the fast-paced world of fashion, few things are more frustrating than unexpected delays in apparel production. For growing brands, delays can mean missed delivery windows, lost revenue, disappointed customers — and a big hit to your cash flow.

At AJG Fashion Consulting, we often help brands understand why production gets held up and how to build a process that minimizes surprises. If you’ve ever asked, “Why does apparel production get delayed?” — this guide is for you.

The Real Reasons Production Gets Stuck

1. Incomplete or Vague Tech Packs
One of the biggest culprits behind delays is an unclear or incomplete tech pack. If your factory doesn’t have every detail — from measurements to construction methods — you’re setting yourself up for extra sampling rounds, revisions, and back-and-forth.

Solution: Invest time upfront in a complete tech pack. Read our guide on why detailed tech packs matter.

2. Sourcing Challenges and Fabric Delays
Sourcing custom or specialty materials can cause major hold-ups — especially if you’re ordering low MOQs, working with new mills, or dealing with import issues. Natural fiber shortages or shipping backlogs can add weeks to your timeline.

Solution: Where possible, work with stock fabrics or plan material development well in advance. Explore our material sourcing tips here.

3. Poor Fit or Quality Issues
Designs that require multiple fit revisions can slow everything down. A single measurement that’s out of spec can mean repeating samples and adding weeks to your development calendar.

Solution: Schedule fit sessions early and often, and use a consistent fit model to catch problems before they snowball.

4. Factory Overcapacity or Limited Capabilities
Your factory’s workload plays a huge role in your production timeline. Smaller or less experienced partners may overpromise — then struggle to deliver on time when orders pile up.

Solution: Choose a factory that’s right-sized for your brand’s volume and complexity. Here’s how to find and work with an ethical manufacturing partner.

How to Stay Ahead of Production Delays

The truth is, some delays are unavoidable — but most can be managed or prevented with good planning. Here are our best quick wins:

• Build in extra time for sampling and approvals.

• Communicate frequently with your production partners.

• Don’t rush development just to hit unrealistic launch dates.

• Keep detailed records of all sample comments and changes.

• Consider nearshoring or reshoring production for shorter lead times and fewer shipping risks. Explore our blog on choosing between domestic and overseas manufacturers.

Final Thoughts

The cost of delays is real — but so are the solutions. With the right team, clear communication, and realistic timelines, your production process can run smoothly, leaving you more time to focus on selling and scaling.

Need help setting up a process that works? Reach out to AJG Fashion Consulting to learn how we help fashion brands build timelines that stick.