Apparel Production

Systems

Contents
Production System?
Apparel Production System
Types Of Apparel Production System
Make Through System
Modular Production System
Assembly Line System
a) Progressive Bundle System
b) Unit Production System
) Selection of Apparel Production System
) Q&A Session

SYSTE
M?

SYSTEM:

A group of interdependent
items/processes that interact regularly
to perform a task

Production System
Transformation

of resources into useful goods and

services through continuously interdependent
processes.

A production system takes inputs and converts

them into outputs.

Discussion

How to manufacture an apparel?

What is an apparel production system?

Apparel Production System

An apparel production system is an

integration of 5 interdependent Ms (Man,
Machine, Material, Method & Money) that
directs work flow and generates finished
products.

Types Of Apparel Production

System
Make
Through
System

Modular
Production
System

Assembly
Line
System

Progressiv
e Bundle
System

Unit
Production
System

Note: Firms may use only one

system or combination of

1. Make Through System

It is the traditional method of manufacture

in which normally an operator makes right
through one garment at a time. That is one
operator will do all the stages of the sewing
operations of one garment and after
completing it he will go for the next
garment

Advantages
The advantages of make through system are

Quick throughput time

Easier to supervise
Reduced WIP levels as compared to other
production systems

Disadvantages

Low productivity

High labor cost

Only very experienced operator can be

used

It is a system only suitable in high fashion

and sample making

2. Assembly Line system

Assembly lines are designed for a

sequential organization of workers, tools or
machines, and parts. The motion of workers
is minimized to the extent possible.

Each operator is assigned only one

operation in this system

Garment components are moved from

operation to operation.

Working Principles of Assembly

Line
Place the tools and the men in the sequence
of the operation so that each component
part shall travel the least possible distance
while in the process of completion.
Use work slides or some other form of
carrier so that when a workman completes
his operation, he drops the part always in
the same place-which place must always be
the most convenient place to his hand and
if possible have gravity carry the part to the
next workman for his operation.

Working Principles of Assembly

Line

Use sliding assembling lines by which the

parts to be assembled are delivered at
convenient distances.

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(PBS)

Parts of various component after being cut

in the Cutting Room are tied up in bundles
and distributed out to the Sewing Section.
This is called the Progressive Bundle System
(PBS).

PBS

PBS

Bundle Tickets attached to cut parts.

One operator is expected to perform the

same operation on all the pieces in the
bundle.

Retie the bundle and set it aside until it is

picked up and moved to the next operation.

Advantages
Labor of all level used, cost of labor is
cheap
Specialized and Rhythm of operation
increase productivity
Allow better utilization of specialized
machines.

Advantages
High Production outputs.
There is less chance of shade variation, size
variation.
Bundle tracking is possible, so identifying
and solving the problems becomes easy.

Disadvantages
Slow Processing.
Balancing the line is difficult.
Increase in WIP in each section increases
the inventory cost.
The system is not very adaptable for short
run production and frequent style changes,
as these require rearrangement of the
workstation

Disadvantages
It requires high level of management skills.
Improper planning causes labor turnover,
poor quality, less production etc.
Individual operators that work in a
progressive bundle system are independent
to others.

(b) Unit Production System

A study by industrial engineers in Sweden

over 30 years ago showed that operators
were only spending 20% of their time
actually sewing.

The rest of the operator's time was spent in

handling materials and dealing with
personal fatigue issues.

Unit Production
System(UPS)

The Unit Production System is usually but

not always an overhead conveyor, which
moves
the
single
product
between
workstations

Unit Production System provides for

improved efficiency, by eliminating highly
unproductive material handling procedures

The underlying theme was to create a

smooth workflow and effectively utilize both
the workers and equipment

How It Works:
*. Load all the pieces in a product carrier.

From bundle to unit

UPS

UPS
To help increase productivity, an
overhead conveyor system was
designed, containing barcoded hangers.
The flexible chain is easily adjusted and
can position units for drop-off directly at
the needle point. All the pieces of one
unit are included in an individual
hanger, and each unit can be pinpointed
throughout the manufacturing process.

UPS

Unit production systems in ETON are linked

to a computer control center that routes
and tracks production and provides up-tothe-minute data for management decisions.

The need for bundle tickets and processing

operator coupons is also eliminated.

Unit Production System.mp4

Advantages
Increased productivity
Improved lead times with less work-inprocess
Improved production and quality monitor

Improved ergonomics
keeps the factory floor clear
Direct & Indirect labor costs reduced

Disadvantages
High cost of installing
Specialized training for the system
Down time is a potential problem

3. Modular Production
System
A group of operator work together to
make product from start to finish .
The number of employees on a team,
usually 4 to 15, vary with the product
mix.
Component of one garment are fed into
flow.

MPS

1,3

Fcng Att to
Pkt
Bag/mouth
(S/N) (4)

Att Pkt Bag

to Frnt &
Pkt Bag to
Back (S/N)
2,4,

Back
Rise
(O/L)
7

Out
Seam ,
O/L Pkt
Bag
(O/L )
9 , 10

Front Rise (O/L)

T/S Front/ Back Rise

(S/N)
6,8

11

Inseam (O/L)

12

Button Hole

14

Jn Tk
Elastic
to Body
(S/N)

TAG /
POLYBAG

IRON /
PRESS

15

Stitch
Waist Band
(SM)

INSPECTION

BIN

Hem Bottom (S/N)

(Swing Folder)
16

Attach
Elastic to
Body (O/L)
13

MPS

MPS
Team
members
cross-trained
and
interchangeable among tasks within the
group.
Teams may be used to perform all the
operations or a certain portion of the
assembly operations depending on the
organization of the module and processes
required.

MPS
Operators are given the responsibility
for operating their module to meet goals
for throughput and quality.
The team is responsible for maintaining
a smooth work flow, meeting production
goals, maintaining a specified quality
level, and handling motivational support
for the team.
Team members are Interdependables.

MPS
A Modular Production System operates as a
Pull System, with demand for work coming
from the next operator in line to process the
garment.
Modules frequently operate as minifactories
with teams responsible for group goals and
self-management.

MODULES WORK ON
PULL SYSTEM;
LINES WORK ON PUSH
SYSTEM.

Advantages
High flexibility
Fast throughput times
Solves absenteeism related problems
Increased employee ownership of the
production process
Empowered employees
Improved Quality

Disadvantages
Highly skilled operators required
High investment in initial training
High cost incurred in continued training
Its difficult for team to accept new member

Modular Production System

Known by many names

Flexible manufacturing
Self directed work teams
Cellular manufacturing units

Better suited to small & Medium production

runs

Performance Measures

Any system Can be evaluated on following

Points

Throughput time
Employee Attitude
Costs
Indirect Labor Ratio
Labor Turnover
Quality

Standardized Parameters
Material=Short Sleeve Crew Neck T Shirt
Qty=1000 pcs
Shift Time=450 min

Findings
Parameters

PBS

MPS

UPS

Throughput

7 Days

3 days

2 days

High

Low

Low

Sqr.ft/opt.

8.5 m2

5.5 m2

5 m2

Efficiency

49%

80%

88%

Fault%

7.2%

2.5%

1%

Quality

Good

Excellent

Excellent

Labor cost

Low

High

High

Indirect labor
cost

High

Low

Very low

Absenteeism

5%

3%

2%

Training cost

Low

High

More
Expensive

Competitive

Cooperative

Cooperative

Poor

Excellent

Medium

WIP

Employee
Attitude
Responsibility

How to Select an Appropriate

Apparel Production System?

Elements And Performance

Criteria
There are 3 elements in selecting an apparel
production system.
1)

Compare Apparel Production Systems.

2)

Evaluate Apparel Production System.

3)

Select Apparel Production System Most

Appropriate for Company Requirements.

1 Compare Apparel Production System

PERFORMANCE CRITERIA:

Comparative system features are outlined.

RANGE: Skill level, Operator flexibility, WIP,
Throughput time.
Systems are compared in terms of space
and equipment requirement for different
products.
RANGE: trousers and skirts, shirts and
blouses, sweat and T shirts, lingerie,
dresses, jackets

2. Evaluate Apparel Production

System
PERFORMANCE CRITERIA:
Systems are evaluated in terms of their
suitability for different products.
Systems are evaluated in terms of their
suitability by production quantity.
RANGE: Quantities 1-10, 11-100, 100-500,
over 500.
Systems are evaluated in terms of system
purchase, installation, and running costs.
Systems are evaluated in terms of flexibility
of production.

3. Select Production systems Most

Appropriate for Company Requirements.
PERFORMANCE CRITERIA
System is selected according to company
requirements.
Throughput times on selected system meet
company requirements.
Implementation requirements are detailed.
RANGE: Training, space requirements,
machinery and/or equipment, time scale.

Thanks

Any

Query.?