A well-planned size run reduces two expensive problems: employees who cannot wear the uniform and excess inventory concentrated in the wrong sizes. The process is not simply choosing equal quantities from XS to 5XL. It requires a defined measurement chart, wearer information, fit validation, and a sensible allowance for replacements and new starters.
Start With One Approved Measurement Chart
Confirm whether the supplier uses body measurements or finished-garment measurements. A chest measurement taken from a shirt laid flat is not the same as a person’s chest circumference. Record the measurement method, tolerance, garment fit, and units in the specification.
Do not assume that “Large” is consistent between factories, countries, or garment types. A polo, tailored shirt, jacket, and work trouser may need different ease allowances.
Collect Useful Wearer Data
For an existing workforce, use a controlled fitting exercise or an employee order form based on the approved samples. Ask staff to select from the actual size chart rather than their usual retail size.
- Separate quantities by garment style and fit.
- Record height or inside-leg options where applicable.
- Identify maternity, adaptive, or special-fit requirements.
- Protect employee information and collect only what is necessary.
- Set a deadline and verify unusual entries before ordering.
Build the Initial Size Distribution
Combine confirmed wearer selections with historical issue data if it exists. If no history is available, use sample fittings from a representative group instead of relying on a generic percentage chart.
| Input | Why it matters | Recommended action |
|---|---|---|
| Current employee selections | Best view of immediate demand | Validate against approved samples |
| Previous issue records | Shows repeat demand and common exchanges | Remove obsolete styles and duplicates |
| New-starter forecast | Prevents early stock-outs | Add allowance by likely role and size |
| Replacement rate | Varies by job and garment | Use operational history where possible |
Add Allowance Deliberately
Extra stock should follow expected demand, not be spread evenly. Common middle sizes often need more buffer, while extreme sizes may be better replenished through planned repeat orders. Consider staff growth, turnover, garment damage, seasonal workers, and the supplier’s reorder lead time.
For custom-dyed or highly branded garments, reorders may require a minimum quantity. Discuss repeat-order support before approving the first order.
Validate Fit Before Final Quantities
Run a size-set review using representative sizes from the production pattern. Check mobility in real tasks: reaching, bending, sitting, kneeling, and layering. Confirm sleeve and body lengths, waist comfort, rise, and movement across shoulders.
Record every approved measurement and tolerance. Verbal feedback such as “make it slightly bigger” is difficult to reproduce. Convert feedback into measurements or pattern adjustments.
Keep the Size Run Easy to Audit
Your purchase order should list style, colour, size, quantity, unit price, and total quantity. The factory packing list and carton labels should follow the same structure. For multi-location programs, add destination or department codes before production begins.
Plan Reorders From Day One
After distribution, record exchanges, shortages, and unused stock. This becomes the basis for the next order. Retain an approved sample and final measurement chart so the supplier can reproduce the fit consistently.
UNIWORKWEAR can prepare size sets and custom measurement charts for B2B programs. Request a quote or review our customisation options.
