With over 15 years in the work uniform business, I’ve seen the consequences of poor sizing: high returns, delayed launches, and frustrated employees. The truth is, getting the sizing right is the single biggest operational challenge for most businesses.
I think a well-executed team fit session, utilizing comprehensive size runs and accurate order forms, is the only way to slash returns, save processing time, and ensure every team member is comfortable and professional from the start. It’s an essential investment in your operational efficiency and employee morale. So, let’s look at the best way to build a uniform that works.
What Is a Uniform Fit Session?
A uniform fit session is a scheduled event where employees try on sample uniforms in a comprehensive range of sizes (a “size run”) before the final bulk order is placed.
Its purpose is two-fold, namely accuracy and functionality. Workwear sizing, whether it’s men’s work pants or hi-vis jackets, often differs significantly from retail clothing, making a try-on essential. This session confirms that the employee’s typical size translates correctly to the manufacturer’s specific cut. Crucially, it allows staff to test the garments for mobility, bending, and lifting—ensuring the uniform doesn’t just look appropriate, but also performs safely and comfortably for their job tasks.
How to Run a Team Fit Session
Based on my experience working with clients across multiple industries, these steps ensure a seamless and successful fitting event.
Plan Ahead: Schedule Early
Schedule your fit sessions early—ideally four to six weeks before you need the order placed. Large uniform orders, especially those requiring custom embroidery, demand extended lead times. Rushing the sizing process inevitably leads to costly mistakes and delays.
Prepare a Size Run
The size run is the foundation of the session. It must be a complete inventory of sample garments, covering every available size (e.g., XS through 5XL, including short, regular, and tall inseams). Every item to be ordered—trousers, shirts, jackets, and specialized footwear—must be available for employees to try on. Ensure you have multiples of common sizes (M and L) to minimize wait times.
Organize Try-On Stations
Create separate, clearly labeled stations for different categories: tops, bottoms, and specialty items like outerwear or safety footwear. Provide mirrors and designated areas where employees can move, stretch, and simulate job tasks while wearing the samples. They need to confirm the fit works under working conditions.
Record Measurements Accurately
As employees try on items, they must finalize their preferred size on an individual order form. I strongly recommend assigning a supervisor or dedicated staff member to oversee this process. This person should double-check the size recorded on the form against the size label of the sample the employee is wearing. This simple verification prevents most recording errors.
Collect Feedback
Use the forms to gather quick, qualitative feedback. A simple note about “comfort for lifting” or “restriction in the shoulders” can highlight potential issues in a specific garment cut. This data allows you to make minor adjustments to the bulk order, ensuring long-term uniform satisfaction for that department.
Tools & Checklists for Accurate Sizing
In my opinion, the backbone of an efficient fitting session is reliable data and the right tools.
- Size Run Checklists: Use a checklist to verify all sample items (e.g., all sizes of polos, jackets, trousers) are present before the session begins. This prevents mid-session crises and avoids placing inaccurate orders due to incomplete sampling.
- Order Forms: The order form must be clear, itemized, and include a supervisor sign-off column. For maximum accuracy and to eliminate handwriting errors, I strongly advise using digital forms accessed via tablets. Digital input moves data straight into a clean spreadsheet, ready for easy order compilation.
Organizing the Session for Efficiency
Time is money. Minimize disruption by adhering to key logistics strategies.
- Group and Schedule: Never try to fit everyone at once. Schedule fitting times that minimize disruption by grouping employees by shift, department, or location (e.g., warehouse crew fittings between 10 AM and 11 AM).
- Clear Management: Set a clear timeline (e.g., 15 minutes per person) and utilize department supervisors. Supervisors are excellent resources for checking forms, managing the flow of traffic, and confirming their team members adhere to the schedule.
Bulk Uniform Ordering & Planning for Extras
After collecting the size data, the final planning step is to plan for extras.
Forecasting Needs and Adding Extra Inventory
You should never order exactly what was measured. I advise clients to add an extra 10% to their total order count, heavily weighted toward the most common sizes confirmed during the fit session. This surplus inventory serves two vital purposes:
- New Hires: Allows you to immediately outfit new staff members without emergency rush orders.
- Replacements: Provides a buffer stock for damaged or lost items, ensuring the entire team remains cohesive and professional without delay.
This minor upfront investment avoids massive future cost and hassle, guaranteeing you have a ready supply of the correct sizes to manage natural team attrition and uniform wear.
Improving Employee Comfort & Morale
For me, the soft benefits of a structured fit session are just as important as the operational ones.
By involving staff directly in the process, I really feel that you send a clear message that you value their comfort and input. This ensures inclusivity, as staff can confirm the fit works for all body types, and it elevates the uniform program in their eyes. A comfortable, correctly fitted employee feels respected and is more confident and productive on the job. The commitment to accurate sizing ultimately boosts long-term employee satisfaction and morale.
Sources
https://www.allseasonsuniforms.com/build-a-uniform-workshop
https://www.allseasonsuniforms.com/mens-unisex-clothing/pants
https://pmc.ncbi.nlm.nih.gov/articles/PMC5285316
https://stacks.cdc.gov/view/cdc/216031
https://www.apa.org/topics/healthy-workplaces/making-difference-at-work
https://www.pmi.org/learning/library/soft-benefits-are-real-9694
About the Author
Nick Warrick
Nick Warrick is the Sales Manager at All Seasons Uniforms. With over 15 years of experience in the work uniform business, he has worked with hundreds of clients across 20 different industries. Holding bachelor’s degrees in both Business Administration and Information Technology, Nick revamped the company’s online presence, offering its customers a new uniform shopping experience.