Sizing and Fit for Uniform Programs
Uniform sizing has two separate questions inside it that buyers often merge into one. The first is what sizes the garment comes in, a grading question, handled in the tech pack. The second is how many of each size to order across a workforce, a distribution question, and the one that actually drives whether a program lands well or leaves you with a stockroom of unworn 3XLs and no mediums.
Size run planning by actual distribution
A size run is the mix and quantity of sizes ordered for a program. The common mistake is ordering an even split across the size range, on the assumption that demand is uniform. It rarely is. The right size run comes from the actual size distribution of the people being outfitted, collected before the order rather than corrected after it.
For a first program, a size survey of the workforce, even a rough one, beats guessing. For a reorder, the previous order's actual fit outcomes (what got exchanged, what ran short) is better data than the original estimate ever was.
Grading and tolerance
Grading is how a base pattern scales up and down into a full size range (for example XS through 3XL) while keeping proportions consistent across every size. Tolerance is the acceptable difference between a garment's specified measurement and its actual measurement, usually in centimeters, stated per point of measure in the tech pack. Both belong in the specification: a size range with no stated tolerance leaves "does this size pass" undefined. See Writing a Uniform Tech Pack for where points of measure and tolerance sit in the spec.
Fit sampling before a full run
Fit is worth confirming on an actual sample, not just on a size chart, especially for a garment type new to your program or a workforce with fit requirements a standard grade may not cover. A fit sample in one or two representative sizes, tried on real staff rather than checked against measurements alone, catches issues a chart can't, how a garment sits during actual movement, whether a role's specific posture or equipment changes the fit. This connects directly to the sampling process in Sampling and Approval.
Handling new staff and reorders
A uniform program isn't static, staff join, and sizes shift. Two questions worth settling with a manufacturer before the first order: can they hold your tech pack and grading for a consistent reorder months later, and is there a smaller reorder path for topping up individual sizes as new staff join, separate from a full bulk run. See Reordering and Managing a Uniform Program for how repeat orders work.
FAQ
How do I decide how many of each size to order? From the actual size distribution of the workforce being outfitted, not an even split across the range. For a first order, survey staff sizes; for a reorder, use the previous order's real fit outcomes, which are better data than any estimate.
What's the difference between grading and the size run? Grading is how the pattern scales across sizes so proportions stay consistent, a garment-construction question. The size run is how many of each size you order, a program-planning question based on your workforce. Grading is set in the tech pack; the size run is decided per order.
Should I order extra stock in common sizes for new staff? Many programs do, but the right buffer depends on expected staff turnover and whether the manufacturer offers a smaller reorder path. Ask about reorder options before over-ordering upfront, holding excess stock in a guessed distribution can cost more than a planned top-up run.
Can one size chart work across different garment types in a program? Not usually. A polo, a structured jacket, and trousers grade differently, so each garment type generally needs its own sizing within the same program, even if they map to the same named sizes (M, L, XL) on paper.
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