Garment Production Systems

In simple a ‘garment production system’ is a way how fabric is being converted into garment in a manufacturing system. Production systems are named according to the various factors, like- Number of machine are used to make a garment, Machines layout, Total number of operators or tailors involved to sew a complete garment and Number of pieces moving in a line during making a garment. As the fashion industry evolved and demand of readymade garments are increased, the need of mass production system becomes the primary path to meet the demand. Simply because tailor shops are not able produce the volume and supply across the world. Mostly used production systems are as following.

Make Through SystemWhen a tailor alone makes a complete garment, then it is called as make though systems. The tailor even makes pattern (use readymade pattern), cuts fabric and does finishing of the garment. For example, tailors in the tailor shops do all jobs from cut to pack. In this system tailors are not depended to others.

Section Production SystemThis system is similar to the progressive bundle system. But the difference is that, instead of one line, work is

divided into sections. Machines of similar operations are clubbed together instead of spreading over in all lines.

For example, when a man’s formal shirt is being made in a section layout – collars, cuffs and sleeves are in the

preparatory sections and then send to the assembly section. This system is popular to improve line balancing

and utilization of human resources. 

Modular Production SystemIn ‘Modular production system’ sewing operators work as a team. Neither they sew complete garment nor do

they sew only single operation. Multi skilled operators form a group and each of the team members do multiple

operations. In modular system, operators help each other to finish the garment quickly and team is fully

responsible for quality and production. In modular, always team performance is measured instead of individual

operator performance. This system is very successful where quick response is needed. 

One Piece Flow SystemInstead of making a bundle of multiple pieces, bundle is made with all components of a single piece. Sewing

machines in One-piece-flow system can be laid in a straight line or modular line. Main difference is that,

operator will receive one piece from back and move one piece to his next operator after completing his work.

Benefits of One-piece-Flow system are less through put time, Less WIP in the line. 

Overhead Production System (UPS -Unit Production system)In overhead production system, garment components are clamped in a hanger and the hanger moves on an

overhead rail. In the hanger components of a single piece is clapped. So this is also one kind of single-piece-

flow system.

Piece Rate Production SystemPiece rate system also one of the most popular production system in small and unorganized factories. Though

people called it piece rate system, actually it is not a production system. Whatever Production system is used as

mentioned above, when operators are paid according their works (how many pieces produced), is named as

piece rate system.

 Assembly Line SystemEach operator is assigned to one operation only,

· Bundles of garment components are moved sequentially from operation to operation

· Bundles consist of garment parts needed to complete a specific operation or garment component.

· Some companies work with varied bundle sizes others with standard bundle sizes

· Bundles are assembled in cutting room where cut parts are matched.

· Bundle tickets consist of a master list of operations and corresponding coupons for each operation.

· Each bundle receives a ticket that identifies style#, size, shade and list of operations (is some cases)

· Bundles are assembled is cutting room where cut parts are matched

· Bundle receives a ticket that identifies style#, size, shade and list of operations.

There are two variations of the assembly line system being followed in the industries namely

· Progressive Bundle systems and

· Unit production system

A. Progressive Bundle system

Machines and operations are organized into sections according to basic functions, which produce sub components.

Within each sections works is balanced according to time required for each sub-functions.

The disadvantages of progressive bundle system are:

Machine investment costs are high.

The system is not very adaptable for short-run production and frequent style changes, as these require rearrangement of the workstation.

· It involves high handling costs for bundle handling and transportation.

· It requires a high level of work in progress and therefore a high capital commitment.

· It requires a high level of management skills to arrange the workflow and decide on the number of operators

· Individual performance can be monitored and incentives offered.

· The advantages of the progressive bundle systems are:

· High productivity

· A high level of labor utilization can be achieved

· Training time and costs can be reduced

· Semi-skilled labor can be used

  B .Unit Production system (UPS) 

Similar to a relay race, each production operator has a task and passes that garment on to the next person. Normally there is only one garment between operations.

As a mechanical system this has been in use for many years, but a major advance was made in 1983 when computers were first used to plan, control and direct the flow of work through the system.

The essential features of this system are:

1. The unit of production is single garment and not bundles.

2. The garment components are automatically transported from work station to work station according to pre-determined sequence.

3. The work station are so constructed that the components are presented as close as possible to the operator’s left and in order to reduce the amount of movement required to grasp and position and component to be sewn.

All the components for one garment are loaded into a carrier at a work station specially designed for this purpose. The carrier itself is divided into sections, with each section having a quick – release retaining clamp which prevents the components from falling out during movement through the system. When a batch of garments has been loaded into carriers they are fed past a mechanical or electronic device which records the number of the carrier and addresses it to its first destination.

ANKUR SHUKLA

APPAREL PRODUCTION management.

THANK YOU.