10b..Apparel Production System

7/16/2019 10b..Apparel Production System

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Knitwear Production Planning

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Apparel Production SystemApparel Production System1.

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

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

Most of the production systems employed in garment factory areMost of the production systems employed in garment factory arederived fromderived from Manual systemsManual systems Mechanical systemsMechanical systems

33Apparel Production Systems an integration of materials handling,Apparel Production Systems an integration of materials handling,production processes, personnel, and equipment that directs work flowproduction processes, personnel, and equipment that directs work flow and generates finished products.and generates finished products.

Most of the production systems employed in garment factory areMost of the production systems employed in garment factory are

derived fromderived from Manual systemsManual systems

Manual systemManual systemSection or Processes SystemSection or Processes System

Progressive Bundle SystemProgressive Bundle SystemStraight-line or Synchro- systemStraight-line or Synchro- system

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

Most of the production systems employed in garment factory areMost of the production systems employed in garment factory arederived fromderived from

Manual systemsManual systemsManual systemManual systemSection or Processes SystemSection or Processes System

Oct 2011 Apparel Production SystemOct 2011 Apparel Production System




Progressive Bundle System (PBS)Progressive Bundle System (PBS)Straight-line or Synchro- systemStraight-line or Synchro- system

Mechanical systemsMechanical systemsSelective Conveyor Belt SystemSelective Conveyor Belt System Unit Production System (UPS)Unit Production System (UPS)

Quick Response Sewing SystemQuick Response Sewing System Modular Production Systems (MPS)Modular Production Systems (MPS) ( Each production system has its own specific operational( Each production system has its own specific operationalcharacteristics )characteristics )

Manual systemManual system

This is essentially traditional method of production This is essentially traditional method of production –– the entirethe entiregarment is assembled by one operator.garment is assembled by one operator.

specific operational characteristics are:-specific operational characteristics are:-SupervisionSupervisionLabourLabourQuality controlQuality controlProductivityProductivity Trough put time Trough put timeLayoutLayout

This type of system is effective when a very large variety of garment This type of system is effective when a very large variety of garmenthave to be produced in extremely small quantities.have to be produced in extremely small quantities.

Exampe - sewing room of a boutique.Exampe - sewing room of a boutique.

Section or Processes SystemSection or Processes SystemOperators specialize in one major component and sew it fromOperators specialize in one major component and sew it frombeginning to end.beginning to end.

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

versatile operators capable of performing all the operations requiredversatile operators capable of performing all the operations requiredfor a specific components. The sections are built according to thefor a specific components. The sections are built according to theaverage garment produced, and includes;average garment produced, and includes;

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





The sewing room would have a number of sections, each containing The sewing room would have a number of sections, each containingversatile operators capable of performing all the operations requiredversatile operators capable of performing all the operations requiredfor a specific components. The sections are built according to thefor a specific components. The sections are built according to theaverage garment produced, and includes;average garment produced, and includes;

Pre-assembling (preparation of small parts)Pre-assembling (preparation of small parts) Front makingFront making Back makingBack making main-assembly (closing, setting collar and sleeves,..)main-assembly (closing, setting collar and sleeves,..) Lining makingLining making Setting liningsSetting linings Finishing operationFinishing operation

specific operational characteristics are:-specific operational characteristics are:-SupervisionSupervisionLabourLabour

Quality controlQuality controlProductivityProductivity Trough put time Trough put timeLayoutLayout

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

Progressive Bundle System (PBS)Progressive Bundle System (PBS)A traditionally employed in apparel production where the task of A traditionally employed in apparel production where the task of assembling the garment is broken down into small operations, andassembling the garment is broken down into small operations, and

bundles of work are progressed down the production line throughbundles of work are progressed down the production line througheach operation in sequence until the assembly process is compete.each operation in sequence until the assembly process is compete.

It requires large quantities of work in progressIt requires large quantities of work in progress

Most stable system- as it absorbs all imbalance because of the amountMost stable system- as it absorbs all imbalance because of the amountof work in progressof work in progress

Straight-line or Synchro- systemStraight-line or Synchro- systemBased on synchronized flow of work through each stages of producingBased on synchronized flow of work through each stages of producinga garment.a garment.

Time synchronization is the most important factor of this system Time synchronization is the most important factor of this systembecause of the flow of work cannot be synchronized if work flow variesbecause of the flow of work cannot be synchronized if work flow variesconsiderably wide.considerably wide.

The manipulation required to balance the standard time may lead to The manipulation required to balance the standard time may lead toillogical combination of operation.illogical combination of operation.





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

Types:- Types:-Chute SystemChute SystemBench SystemBench System

To be effective , the system requires To be effective , the system requires Volume productionVolume production Accurate line balancingAccurate line balancing Skilled supervisorSkilled supervisor Reserve operatorsReserve operators Reserve machinery and equipmentReserve machinery and equipment

Selective Conveyor Belt SystemSelective Conveyor Belt System The system reduces the handling of work to a minimum and maintains The system reduces the handling of work to a minimum and maintainsthe work in progress at very low levels.the work in progress at very low levels.

Automatic feeding of work containers to an operator and eliminatingAutomatic feeding of work containers to an operator and eliminatingtime consuming fetch and carry methods.time consuming fetch and carry methods.

A typical conveyor systemA typical conveyor systemMain conveyorMain conveyor

Top belt Top beltLower beltLower belt

Unit Production System (UPS)Unit Production System (UPS)

An advanced apparel manufacturing system in which a single garmentAn advanced apparel manufacturing system in which a single garmentis progressed through a sequence of operations. Using a unitis progressed through a sequence of operations. Using a unitproduction system, a garment is automatically transported via aproduction system, a garment is automatically transported via acomputer-controlled overhead hanging system.computer-controlled overhead hanging system.

Which has been ergonomically designed to reduce the amount of Which has been ergonomically designed to reduce the amount of

handling of the garment.handling of the garment. It is a single garment and not bundle is handled at a timeIt is a single garment and not bundle is handled at a time

The garment component are automatically transported The garment component are automatically transported ––on a preon a pre determined sequence.determined sequence.





The work stations are constructed as close as possible The work stations are constructed as close as possible –– so theso thecomponents are sewn without removing from system in most sequencecomponents are sewn without removing from system in most sequence

Quick Response Sewing SystemQuick Response Sewing SystemFor orders are small lotFor orders are small lot

Each station equipped with 4 / 5 machinesEach station equipped with 4 / 5 machines

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

Modular Production Systems (MPS)Modular Production Systems (MPS)

MPS is a contained , manageable work unit that imcludes anMPS is a contained , manageable work unit that imcludes an

empowered work team, equipment, and work to be executed.empowered work team, equipment, and work to be executed.

Modules frequently operate as minifactoryies with teamsModules frequently operate as minifactoryies with teams

responsible for group goals and self- management. The number of responsible for group goals and self- management. The number of

teams in a plant varies with the size and needs of the firm andteams in a plant varies with the size and needs of the firm and

product line. A factor contributing to the success of this type of product line. A factor contributing to the success of this type of

operation is the flexibility of being able to produce a wide variety of operation is the flexibility of being able to produce a wide variety of

products in small quantities.products in small quantities.

Progressive Bundle System (PBS)Progressive Bundle System (PBS)

The bundle system of garments part that are moved sequentially from

operation to operation. This system is also referred to as the

Traditional production system for several decades.


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10b..Apparel Production System