3 Problems Apparel Factories Face in Costing (and How AI is Solving Them)

At Seamstream's launch webinar we spoke with Diana Kakkar from MAES London and Prasanta Sarkar from Online Clothing Study fame, about the the potenial of AI to change the way AI, BOM's and costing. These were the key points they raised -

1. Costing Takes Too Long

AI can make it quicker, especially for commonly made styles

Many factories spend anywhere between 2-3 days to 2 weeks completing a single costing sheet - even for garments which are similar to the ones they have produced before, for the same brand. The back-and-forth between teams and managing multiple Excel files ups create unnecessary delays.

With AI, costing can now be done in under 10 minutes. Seamstream automatically builds the BOM and operation breakdown, giving teams a head start — while still allowing for custom adjustments based on factory realities.

“Before, costing needed 3 days. With AI, we can do it in 10 minutes and still adjust for factory reality.” – Prasant Sarkar

2. Small Mistakes = Big Losses

AI can make the first pass of BOM' and OB's

A wrong zip length or missing trim can delay production, miss delivery windows, and cost business. AI is useful for making the first pass, passing on the data entry burden and freeing up time for more detailed quality checks.

Seamstream’s AI double-checks components, asks for what’s unclear, and creates clean BOMs that reduce human error.

“Even one wrong zip can ruin a line and miss a delivery. This tool helps us catch those errors early.” – Diana Kakkar

3. Every Factory Is Unique

AI can adapt when made aware of the differences

No two factories work the same way. One uses a collar jig, another doesn’t. One has specific machine types or standard times (SMVs) others don’t.

Seamstream’s AI learns how each factory operates — and remembers it. So over time, it adapts to your processes and preferences, making it a tool that fits your way of working.

“Each time we teach it something, it remembers. That’s how it becomes a really useful tool.”  – Simon Johnson

The Future of Factory Workflows

As factories continue to face pressure to do more with less — faster, more accurately, and more profitably — AI is no longer a futuristic concept. It’s a practical solution for everyday manufacturing challenges.