"Sewing itself is very fast so why does it take so long to get finished product out the door and why does it cost so much? As I mentioned in my book, you can have a much greater effect on reducing production sewing time and problems in the design phase than you can in production and today I’m going to show you how.
Sewing a seam is very inexpensive on the face of it but because sewing is measurable, that is how costs are calculated. People look at a seam and mentally put a price to it. Whether it is ten cents, a penny or tenths of a penny, it really doesn’t matter (no, it really doesn’t).
It is not sewing that costs -it’s handling. The problem with handling is that it is mostly invisible; it can’t be measured. If it can’t be measured, you’re not paying for it directly, only indirectly and in the worst ways with bad quality, delays, missing pieces, and dirtied goods. So the trick to reducing a lot of cost is to analyze your seam design to reduce handling points. It seems more effective to analyze seams for the number of handling steps and assign a value based on cost and complexity for each seam. Ideally, each seam would only be one point. More points are justified if the price points support it or the material or finish require it."