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How Fashion Happens in Hawaii

Going behind the scenes to follow local clothes from inspiration to the store rack

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When people think about the fashion business, they tend to focus on the designer’s creative ideas and the finished products they buy. The beginning and the end. But it takes a great deal of work – and many hands – to get that garment from sketch to sales rack.

To understand the process, we went behind the scenes to trace a garment from inspiration to completion. To do that, we selected two Hawaii companies, each with a different business model: Jams World, one of Hawaii’s biggest fashion companies, and UMEE, a much smaller operation.

Jams World

Jams World is celebrating its 50th year in business and currently earns about $6 million a year in revenue. Founded by Hawaii fashion legend Dave Rochlen, it is now run by Pua Rochlen, the founder’s youngest son.

Jams World does most of the work itself and even runs six of its own stores on three islands – though it also uses local contractors for some designs and sells through retailers across the mainland and around the world. Seventy-five people work at the Kalihi factory and another 20 in the local shops.

Even the catalogue is a family and friends affair. Rochlen’s wife, Heather, rents a camera and gathers daughter Savannah Forti and her Kaiser High School friends to act as models for a day. They go on location at a beach or someone’s home and shoot the photos. Mother and daughter then complete the layout together for a fresh and young look.

In recent years, Jams World has ventured into the licensing business. Collaborations include bags with Nixon and Kippy’s, and shoes with Converse. Coming soon: Jams World sunglasses.

Inspiration

Pua Rochlen finds inspiration in many places. For instance, he bought a vintage dress in a French boutique on Carnaby Street in London. His design manager, Doreen Minami, took off layers of fabric and an inch here and there to create the Connie dress. 1 In other cases, Jams World has gone back through its own archives for inspiration, modernizing a design from the ’60s, ’70s or ’80s.

Fabric

Jams World works with textile artists, mainly in Como, Italy, to create its colorful prints. That means Rochlen will travel to textile art shows in Paris or Como to see the original art. Nearly all of the company’s art is hand painted. “Computer-generated art just doesn’t have the right feel for us,” Rochlen says.

Jams World fabrics have always been printed in Wakayama, Japan. The company currently uses a unique crushed rayon that drapes well and takes dyes beautifully.

Pattern

Minami works with pattern maker Mei-Li Greenleaf to determine how the print and pattern will play together. “It takes at least four times to get the pattern right,” Minami explains. For example, the Connie dress is cut on the bias and the bust is fitted, so the hem can easily become higher in the front than in the back. A little elastic was inserted at the empire waist and in the back for a better fit. It was decided to make the straps adjustable to work for more women. Even a Jams World style that has been successful for years may get modified and updated. For example, the next iteration of the Connie will be more bra-friendly, Minami explains, with a higher back and wider straps.

Grading

Unless a garment is one size only, it must be graded, or sized, to small, medium and large or sizes 2, 4, 6, 8 and so on. Jams World has its own computerized grading system, which works well for its shirts and some other garments, but not for those with engineered prints. An engineered print means the print can go in only one direction, and must be placed strategically on the garment. A border print, for example, is an engineered print.

Marker Making

When manufacturing garments, it’s important to maximize the use of fabric and waste as little as possible. This is done by creating a marker, 2 which scientifically lays out the fabric pieces for maximum use.

The Connie dress requires an engineered print, therefore the layout must be done by hand. Maribel Duldulao tries to find the most efficient way to lay out the dress, perhaps finding a use for the excess fabric, such as visors or bags. There is always the question: Is it worth the waste to have this garment engineered? Sometimes a pocket on an aloha shirt may be left off simply to give the shirt a cleaner look and avoid the issue of the pocket being matched exactly to the body of the shirt.

Cutting

While most factories stack up hundreds of garments to cut all at one time, Jams World can only cut about 20 at a time because of the slippery nature of crushed rayon. 3 Sometimes the marker needs to be adjusted after seeing how the pattern is laid out in relation to the print. The first time it laid out the Connie dress, Minami discovered that one side of the bodice was nearly all navy and the other was nearly all white. This required moving the pattern on the marker for a more pleasing effect.

Notions

Rochlen has all the buttons for Jams World garments made by an “old hippie and his buddies” in California who hand paint every one with designs or spatters. Minami chooses and orders buttons specifically to match each garment. This is a costly endeavor. Each button is 30 cents and a shirt requires seven buttons. 4

Sample Making

Jams World uses a sample model but it also tries the garments on some women who work in the factory. Minami and Duldulao scrutinize the sample for every detail. How does the circle skirt drape and is it shorter in the front than in the back? Can a bra be worn under it? How much elastic is needed for the right amount of stretch, without scrunching or cinching?

Sales

In 2008, as the economy nose-dived, buyers were “leery of anything new,” Rochlen says, so he opened Jams World stores to be directly in touch with customers. There are now six retail stores: two each on Oahu, Maui and Hawaii Island.

Jams World also goes to the WWIN trade show in Las Vegas, also known as Women’s Wear in Nevada, where buyers from all over the country congregate. Jams World clothing is sold in hundreds of boutiques. They have sales representatives in the Caribbean, California, the Southeast and Hawaii. “Our market is wherever the sun shines a lot,” Rochlen says.

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