10a...Apparel Production Systems

7/28/2019 10a...Apparel Production Systems

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Knitwear Production Planning & Control

Apparel Production Systems

Apparel Production Systems an integration of materials handling, production processes,

personnel, and equipment that directs work flow and generates finished products.

Apparel Production Systems an integration of materials handling, production processes,personnel, and equipment that directs work flow and generates finished products.

Most of the production systems employed in garment factory are derived from

Manual systems

Making Through (Manual system)Section or Processes System

Progressive Bundle System (PBS)

Straight-line or Synchro- system

Mechanical systemsSelective Conveyor Belt System

Unit Production System (UPS)Quick Response Sewing System

Modular Production Systems (MPS)

( Each production system has its own specific operational characteristics )

1. Manual system (Making Through)

This is essentially traditional method of production the entire garment is assembled by

one operator.

This type of system is effective when a very large variety of garment have to be produced

in extremely small quantities.

Example - sewing room of a boutique.

Major features of the system are;

Supervision :- The requirement are minimal because the operators deside on their own

working methods.

Labour:- As highly skilled labours are used for the simplest of operations, cost are

relatively high when compared with other systems.

Quality:- high quality is required.

Sept 2010 Intro to Indian Apparel Sector 1


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Productivity:- due to lack of specialization, this system is not effective for high volume

production.

Throughput Time:- it is not necessary.

Layout:- Any convenient arrangement of machinery.

2. Section or Processes System

Operators specialize in one major component and sew it from beginning to end.

The sewing room would have a number of sections, each containing versatile operators

capable of performing all the operations required for a specific components. The sectionsare built according to the average garment produced, and includes;

Pre-assembling (preparation of small parts)

Front making

Back making

main-assembly (closing, setting collar and sleeves,..)

Lining making

Setting linings

Finishing operation

specific operational characteristics are:-


MakingSmall

component

Makingback

MakingFront

Finish

SetCollars

Andsleeves

ClosingBacks

& Front


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Supervision :- this has to ensure the correct movement of work from section to section.

Labour:- As labour with varing skills can be used , the system is cheaper.

Quality:- due to the various levels of operator skill, in-process quality contro has to bevery thorough.

Productivity:- higher than the manual making through system.

Throughput Time:- this is longer due to the large quantities of work in process.

Layout:- this would be planned according to the processs folw of the average garmentproduced.

This is a very efficient system for producing a variety of styles in reasonable quantities.

3. Progressive Bundle System (PBS)

A traditionally employed in apparel production where the task of

assembling the garment is broken down into small operations, andbundles of work are progressed down the production line through

each operation in sequence until the assembly process is compete.

It requires large quantities of work in progress

Most stable system- as it absorbs all imbalance because of the amount of work in

progress


Supervision :- This system is not just involved in ensuring the correct movement of work

between sections, but is concerned with the movement and balance of work with in the

section.

Labour:- This can be of various skill and cost levels because, the more complex the

operations are broken down into a series of small and relatively simple operations.

Quality:- In-process quality control is now involved in inspecting individual component

rather than complete product

Productivity:- productivity is higher than most of the other system, due to the breakdown

of operations and possible introduction of specialized machines.

Throughput Time:- This is considerably increased due to the amount of work stored atthe beginning and at the end of each section.



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Layout:- This is important because the end o one section must be positioned adjusent to

the start of the section which perform the following series of operations.

4. Straight-line or Synchro- system

Based on synchronized flow of work through each stages of producing a garment.

Time synchronization is the most important factor of this system because of the flow ofwork cannot be synchronized if work flow varies considerably wide.

The manipulation required to balance the standard time may lead to illogical combination

of operation.

It is a very rigid system and particularly vulnerable to absenteeism and machine

breakdown.

Types:-

Chute SystemBench System

To be effective , the system requires

Volume production

Accurate line balancing

Skilled supervisor

Reserve operators

Reserve machinery and equipment


Supervision :- Due to the rigidity of the system, supervisor are very mush concerned

with the line balance at the times. Every minor delay could have serious repercussions.

Labour:- The operators require relatively high skill levels, in order to maintain a time

balance between the operations in the line.

Quality:- In-process quality control must be more alert and intensive, because hold-up

caused through quality problem can stop the line in a matter of seconds.

Productivity:- Productive levels can be very high due to the regular pace of the

successive operations.

Throughput Time:- This is very short as a result of the quantity of work I process.

Layout:- the simplest layout system, as on eoperator is seated next to, opposite to thenext one.



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5. Selective Conveyor Belt System

The system reduces the handling of work to a minimum and maintains

the work in progress at very low levels.

Automatic feeding of work containers to an operator and eliminating time consuming

fetch and carry methods.

A typical conveyor system consists of;

Main conveyor

Top belt

Lower belt


Supervision :- the supervisor is relieved of the task of work feeding and ia able to spentmore time working with the operators.

Labour:- All grades and rates

Quality:- In-proces system are operated.

Productivity:- Reasonable high because in an efficient run unit there is continual flow of

work.

Throughput Time:- still measure in days because of the amount of work in progress.

Layout:- a very compact straight line.

6. Unit Production System (UPS)

An advanced apparel manufacturing system in which a single garment

is progressed through a sequence of operations. Using a unit

production system, a garment is automatically transported via acomputer-controlled overhead hanging system.

Which has been ergonomically designed to reduce the amount ofhandling of the garment.

It is a single garment and not bundle is handled at a time

The garment component are automatically transported on a pre determined

sequence.



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The work stations are constructed as close as possible so the components are

sewn without removing from system in most sequence


Supervision :- freed to work with the operators.

Labour:- All grades and all rates

Quality:- In-process inspection ststions are built into the line.

Productivity:- High bacuse the operators are working in a paced environment.

Throughput Time:- thi is measures in hours instead of days.

Layout:- Can be of any form suitable to the availability area.

7. Quick Response Sewing System

For orders are small lot

Each station equipped with 4 / 5 machines

Many operations are completed in that work station before it is transported to other.


Supervision :- freed to work with the operator

Labour:- high skilled . different operations re at one work station.

Quality:- In process inspections are built into the line.

Productivity:- very igh.

Throughput Time:- is extremely short as few garments are in the line

Layout:- A typical unit will have eight work stations arranged around the transportsystem.

8. Modular Production Systems (MPS)

It is a contained, manageable work units (modules) that includes an empowered workteam, equipment, and work to be executed.



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Modular system frequently operates as mini-factories with teams, usually five to fifteen

people, responsible for group goals and self-management.

Team members are interchangeable among tasks within the group to the extend practical.

Modular units may be used to perform all the operations for a garment or a certainportion of the assembly operations depending on the organization of the module and

assembly processes.

A module may be divided into several work zones based on the balance of work needed

in the module. A work zone consists of a group of sequential operations. Operators are

trained to perform the operations in their work zones and adjacent work zones.

Work flow with in a module may be with a single piece-hands-off, a Kanban, or a

bumb-back system.

If a single piece-hands-off is used, machines are arranged in a very tight configurationwith an operator at every machine. As soon as an operation is completed the part is

handed over to the next operator for processing. A kanban uses a designated work spaceto balance supply with demand. If the designated space is full, there is no need to produce

more until it is needed or the space is empty.

Many different name are currently used to identify modular apparel production systems,

includes cellular manufacturing units, compact work teams, flexible work groups, self-

directed work teams, and Toyota Sewing System(TSS). The basic s is similar among

these systems, although the organizations and implementation may vary.

A bumb-back system approach, developed by Toyota sewn products management system,

is a stand up module of flexible work zones and cross-trained operators. Operators maybe cross trained o up to four different successive operations


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10a...Apparel Production Systems