Overproduction is Over: Why Made-to-Order is the Smarter Option

Every year, the fashion industry produces over 92 million tonnes of textile waste globally. In fact, in the UK alone, it is estimated that we send £140 million worth of clothing to landfill annually. Much of this waste comes from overproduction, where excess stock goes unsold and eventually ends up in landfills. In an age where ethics and sustainability are non-negotiable, the fashion industry must find ways to cut back on such unnecessary waste. 

In the uniform sector of the fashion industry, one forward-thinking solution is the made-to-order model. This aligns perfectly with the growing demand for sustainable, cost-effective, and customisable work uniforms. 

But why is this model the smarter option? In this article, the experts from Jermyn Street Design will explain fashion’s overproduction problem and explore the environmental, financial, and ethical benefits of moving towards made-to-order production for bespoke uniforms.

Understanding Overproduction and Its Widespread Impact

Overproduction occurs when more products are manufactured than needed, driven by factors like inaccurate demand forecasting, minimum order requirements, and the mindset of producing in bulk “just in case.” 

While this model has long been the norm, it comes with significant consequences for both businesses and the environment. Clothes Aid research has actually found that 30% of the UK’s unwanted clothing currently goes to landfill.

Hidden Financial Costs

Overproduction doesn’t just harm the environment – it also eats into business profits. Unused stock needs to be stored, and storage fees can add up quickly. Disposal costs for unsold uniforms can further burden businesses, turning overproduction into a costly misstep.

Ethical Concerns

There are also ethical issues to consider. Overproduction often leads to rushed and high-volume production, which can result in unsafe working conditions for garment workers. Companies are increasingly being held accountable for the treatment of workers within their supply chain, and overproduction can contradict corporate sustainability and social responsibility goals.

The Shift Towards Made-to-Order Uniforms

What is Made-to-Order?

Made-to-order is a production model where uniforms are created based on actual demand, meaning each item is only created once it has been ordered. This stands in stark contrast to traditional mass production, where large quantities of uniforms are made upfront, often with limited regard for precise demand forecasting. Made-to-order reduces waste by ensuring that every item has a designated wearer, thus eliminating surplus stock.

Technological Advancements

In recent years, advances in technology have made the made-to-order model more viable and cost-effective. Advanced manufacturing techniques, digital pattern-making, and 3D fitting simulations have streamlined production processes, allowing for high-quality bespoke uniforms to be made efficiently and at scale. These innovations have empowered industries to move towards more sustainable practices without sacrificing speed or quality.

Industries Leading the Way

Several sectors have already embraced the made-to-order model for work uniforms. For instance, the hospitality industry benefits from bespoke uniforms that reflect brand identity and employee comfort. Airline companies like Titan Airways and Jet2 have also seen success with made-to-order uniforms, ensuring both sustainability and a polished, professional look. Similarly, in healthcare and other client-facing services, made-to-order uniforms reduce waste while offering the fit and functionality healthcare workers need.

Key Benefits of Made-to-Order Work Uniforms

1. Sustainability and Environmental Benefits

Made-to-order work uniforms significantly reduce textile waste and the overall carbon footprint of production. By focusing on need-based production, companies conserve natural resources like water and cotton, all while minimising waste. This model also aligns with circular economy principles, encouraging companies to only use what is required, thus creating a more sustainable approach to uniform production.

2. Cost Efficiency and Inventory Management

Financially, made-to-order can save businesses money by reducing the need for vast warehouses to store unsold stock. Moreover, companies can avoid the steep markdowns and disposal costs associated with overproduction. With made-to-order uniforms, businesses only pay for what they truly need, eliminating the waste and financial burden of excess stock.

3. Customisation and Employee Satisfaction

One of the standout advantages of made-to-order uniforms is the customisation it allows. Bespoke uniforms can be tailored to fit specific job roles or individual needs, improving both comfort and functionality. Well-fitted uniforms can also have psychological benefits, boosting employee confidence and job satisfaction. When workers feel comfortable and well-presented, their performance and morale improve, which in turn benefits the business.

4. Quality Control and Brand Consistency

Smaller, demand-driven production runs allow for stricter quality control when producing bespoke work uniforms. This ensures that every piece meets high standards, enhancing both durability and appearance. Well-made work uniforms also contribute to a positive brand image. When employees are seen wearing high-quality, well-fitted uniforms, it reflects the company’s attention to detail, commitment to excellence, and care.

Aligning Made-to-Order with ESG Goals

Environmental Goals

For companies like JSD who have a strong commitment to Environmental, Social, and Governance (ESG) goals, made-to-order uniforms are an excellent strategy for reducing your brand’s carbon footprint and minimising waste. By producing only what is needed, businesses can contribute meaningfully to their sustainability targets, supporting national and global efforts to mitigate environmental degradation.

Social Responsibility

Demand-based production also promotes better working conditions, as it allows manufacturers to focus on quality of production rather than producing a large quantity of rushed, high-volume orders. Businesses can further enhance their social responsibility by working with local or ethically responsible uniform suppliers. JSD is proud to take full responsibility for the ethical good standing of our factories worldwide, with a focus on safe working environments, fair wages, and good labour practices.

Governance and Transparency

Made-to-order uniforms improve transparency within the supply chain. Companies can track every step of the production process, ensuring ethical sourcing and manufacturing. This level of accountability builds stakeholder trust and helps companies meet stringent reporting requirements under modern ESG frameworks.

Real-World Case Studies of Made-to-Order Uniforms

Businesses that have successfully implemented made-to-measure uniforms have seen the benefits of this tailored approach in improving sustainability, brand image, and employee satisfaction. 

Take, for instance, our work with David Lloyd Leisure. Since the health and fitness operator launched in 2001, JSD has supplied them with versatile made-to-order work uniforms. JSD’s thorough understanding of David Lloyd Leisure’s business not only ensures that their corporate clothing is durable and tailored perfectly to the brand image, but also allows for accurate forecasting of staff uniform needs, helping to reduce waste. 

According to the Head of Procurement at David Lloyd Leisure, “Jermyn Street Design provides the full package: first class warehousing and logistics, friendly and proactive customer support, plus thorough reporting and account management”.

High-end charter airline Titan Airways has also partnered with JSD to create bespoke uniforms that align with their sustainability goals while conveying a classy, professional appearance. Their 2017 cabin crew uniform redesign saw careful consideration of maintaining the brand’s strong, luxury identity, while incorporating unique design features and sustainable practices such as pattern placement that kept wastage to a minimum.

FAQs About Made-to-Order Uniforms

Q: What is the typical turnaround time for made-to-order uniforms? 

A: It depends on a number of factors, but with modern technology and good communication and modern technology that allows for real-time order management, many orders can be designed, manufactured, and fulfilled in a matter of months.

Q: How do made-to-order uniforms impact overall uniform costs? 

A: There is a misconception that made-to-order uniforms are more expensive. While initial costs may be higher, when considering the total cost of ownership – including long-term savings in inventory, storage, and markdowns – made-to-order often proves to be the more economical, cost-effective option. 

Q: Can made-to-order still offer variety in design? 

A: Absolutely! Made-to-order work uniforms can be customised to fit any design requirements.

Ready to Transform Your Uniform Strategy?

In an era where sustainability, cost-efficiency, and personalisation are paramount, made-to-order work uniforms are the smartest choice for businesses across a wide variety of sectors. 

If you’re ready to make the shift, JSD offers expert consultations to help you transition to a made-to-order model. 

Contact us today by filling out our contact form, calling 020 8563 5000, or emailing [email protected] to explore how we can support your bespoke uniform needs.