Costume Order to Delivery: Detailed Overview
Complete visualization of our primary value stream with inputs, outputs, and decision points.
Full Process Diagram
CLIENT INQUIRY
│
▼
┌─────────────────────────────────────────────────────────────────┐
│ STAGE 1: ORDER RECEPTION (1 day) │
│ │
│ Input: Client inquiry (email/phone/meeting) │
│ Owner: Client Relations Manager │
│ │
│ Activities: │
│ ├─ Receive brief (character, event, timeline) │
│ ├─ Estimate timeline & cost │
│ └─ Establish communication plan │
│ │
│ Output: Documented brief + timeline + signed agreement │
│ Decision: Proceed with project? [YES/NO] │
└─────────────────────────────────────────────────────────────────┘
│
▼ [YES]
┌─────────────────────────────────────────────────────────────────┐
│ STAGE 2: DESIGN DEVELOPMENT (5-7 days) │
│ │
│ Input: Approved brief + client requirements │
│ Owner: Creative Director │
│ │
│ Activities: │
│ ├─ Research character & context │
│ ├─ Concept sketches (3-5 options) │
│ ├─ Material selection & sourcing │
│ └─ Client presentation & approval │
│ │
│ Output: Approved design + material list + color palette │
│ Decision: Design approved? [YES/REVISE] │
└─────────────────────────────────────────────────────────────────┘
│
▼ [YES]
┌─────────────────────────────────────────────────────────────────┐
│ STAGE 3: PATTERN MAKING (3-5 days) │
│ │
│ Input: Approved design + client measurements │
│ Owner: Pattern Maker │
│ │
│ Activities: │
│ ├─ Collect/verify measurements │
│ ├─ Draft pattern pieces │
│ ├─ Create mockup/toile if needed │
│ └─ Generate technical specs │
│ │
│ Output: Final pattern + cut list + construction notes │
│ Decision: Pattern fits? [YES/ADJUST] │
└─────────────────────────────────────────────────────────────────┘
│
▼ [YES]
┌───────────────────── ────────────────────────────────────────────┐
│ STAGE 4: PRODUCTION (7-14 days) │
│ │
│ Input: Pattern + materials + technical specs │
│ Owner: Production Manager │
│ │
│ Activities: │
│ ├─ Cutting (1-2 days) │
│ ├─ Sewing & assembly (3-7 days) │
│ ├─ Finishing & embellishment (2-4 days) │
│ └─ Quality inspection (1 day) │
│ │
│ Output: Completed costume + quality checklist │
│ Decision: Passes quality? [YES/REWORK] │
└─────────────────────────────────────────────────────────────────┘
│
▼ [YES]
┌─────────────────────────────────────────────────────────────────┐
│ STAGE 5: DELIVERY (1-2 days) │
│ │
│ Input: Quality-approved costume │
│ Owner: Client Relations Manager │
│ │
│ Activities: │
│ ├─ Schedule final fitting │
│ ├─ Make minor adjustments if needed │
│ ├─ Package with care instructions │
│ └─ Handover to client │
│ │
│ Output: Delivered costume + care guide + satisfaction survey │
│ Decision: Client accepts? [YES/ADJUST] │
└─────────────────────────────────────────────────────────────────┘
│
▼ [YES]
PROJECT COMPLETE
Stage Dependencies
Order Reception ──────┐
▼
Design Development ──────┐
▼
Pattern Making ──────┐
▼
Production ──────┐
▼
Delivery
No stage can begin until the previous stage is complete and approved.
Critical Path
The minimum time to complete the value stream (assuming no revisions):
1 day (Reception) + 5 days (Design) + 3 days (Pattern) + 7 days (Production) + 1 day (Delivery) = 17 days minimum
Typical time with one revision cycle: 21-23 days Maximum time with multiple revisions: 29 days
Decision Gates
Each stage has a quality gate that must be passed:
| Stage | Decision Gate | Pass Criteria | Failure Action |
|---|---|---|---|
| Reception | Proceed? | Clear brief, timeline agreed | Refine brief |
| Design | Approved? | Client signs off on design | Revise design |
| Pattern | Fits? | Mockup approved or measurements verified | Adjust pattern |
| Production | Quality? | Passes inspection checklist | Rework |
| Delivery | Accepted? | Client satisfaction >8/10 | Minor adjustments |
Handoff Points
Clear handoffs between positions:
- Client → Client Relations Manager: Initial inquiry
- Client Relations → Creative Director: Approved brief
- Creative Director → Pattern Maker: Approved design + measurements
- Pattern Maker → Production Manager: Final pattern + specs
- Production Manager → Client Relations Manager: Quality-approved costume
- Client Relations Manager → Client: Final delivery
Common Bottlenecks
Based on historical data:
- Design Approval (Stage 2): Client indecision adds 2-3 days
- Material Sourcing (Stage 2): Specialty fabrics add 3-7 days
- Embellishment Work (Stage 4): Complex details add 2-5 days
- Final Fitting (Stage 5): Scheduling delays add 1-2 days
Stream Metrics
See Metrics for detailed tracking:
- Lead Time Distribution: Track actual vs. target
- Bottleneck Analysis: Where delays occur most
- Quality Scores: Pass rate at each gate
- Client Satisfaction: Final survey results
Last Updated: 2026-02-02 Maintained By: Production Manager