The document discusses various garment production systems including make through, progressive bundle, unit production, and modular production systems. It provides details on the operational principles, components, advantages, and disadvantages of each system. Project management tools like Gantt charts and software are also described which can help plan and schedule garment production. Finally, it concludes that the best system depends on factors like product type, company policies, and available resources.

1. Submitted by:
Azizur Rahman Pappu (191-036-111)
Hasibul Hasan Shanto (191-033-111)
Sarfaraz Hossain (191-034-111)
Fozle Rabbi Tushar (191-022-111)
Tanvir Hasan (191-024-111)
Tayeeba Alam Eliza (191-050-111)
APPAREL
PRODUCTION
MANAGEMENT
Submitted to:
Engr. FARUK AHMED
Assistant Professor, IE, BUFT
M. Eng. in AEM, IPE, BUET
MBA in OPM, IBA, DU
B.Sc. Engineering in ME, BUET
Trained in Apparel Production Management, BIFT; Ex
I.E of OPEX Group and Elite Garment Identifier: FQA,
E-mail: faruk@buft.edu.bd
Office: 518, Contact: 01928371876
BGMEA University of Fashion and Technology (BUFT)
Topic: Garments Production system

2. INTRODUCTION:
• The garment production systems are a combination of production processes,
materials handling, personnel and equipment that direct workflow and produce
finished garments.
• The choice of best apparel production system depend on the Product, The Policies
of the Company and the capacities of manpower.
• There are basically three Production systems:
• Progressive Bundle System
• Unit Production System
• Modular Production System

3. Make through system in Garments:
It is the conventional method of production line where an operator
assembles a single piece of garment at a time by carrying out all the
sewing processes necessary to assemble a garment. After completion of
assembling one garment, the operator will start assembling the next one
and so on. In this system, an operator would be provided with a bundle
of cut work pieces and would continue to assemble them based on his or
her own method of work. This type of system is efficient when a huge
category of garment styles has to be produced in very few quantities. As
a example When a tailor alone makes a complete garment, then it is
called as make though systems.

4. Progressive bundle system (PBS):
 Name implies the bundle of
garments parts move from
operation to operation
 Traditional production
system
 Widely used by apparel
manufacturers for several
decades and still today.
 A ticket number will be
needed.

5. Features of progressive bundle System:
 Sewing operations are laid out in sequence.
 Each operator receives a bundle, does his work, reties the bundle and passes it
to
the next operator.
 There is a storage facility such as rack, bin or table for storing the inter-process
work between each operation.
 The work is routed by means of tickets.
 Machines and operations are organized into sections according to basic
functions,
which produce subcomponents.
 Within each section, works are balanced according to the time required for each
sub-function.
 The amount of machinery for each operation is determined by the output
required.
 It is used in shirt factories, jeans factories, jacket factories, etc.

6. progressive bundle System:

7. progressive bundle System:
Advantages: Disadvantages:
• It allows high productivity.
• A high level of labor utilization can be
achieved and helps in reducing time and cost.
• Laborer of all levels (unskilled, skilled, semi-
skilled labors) are involved in this system.
• Individual performances can be monitored
and incentives offered.
• Due to bundle system, less chance to lot mix-
up, size and shade variation of cut garment
pieces.
• Tracking of bundles is possible
• Time-consuming due to assembling, moving,
tying and untying of bundles.
• Line balancing becomes difficult most of the
time and this problem is solved by effective
production supervisor and IE Engineers.
• Large inventory, extra handling and difficulty
in controlling inventory.
• Inventory cost will be high due to higher WIP
in each.
• Proper planning is required for each batch and
for each style, which takes lot

8. Unit production system (UPS):
• A unit production system is a type of layout that uses an overhead transporter system to move
garment components from work station to work station for assembly

9. Operational Principles of Unit Production System:
This system is designed based on the following principles:
1. An operator set the process in the control station.
2. Worker loads the cut pieces in a hanger from the loading station
3. The hanger routes to the next workstation automatically according to the predetermined process in the control station.
4. Product is put together at every stage at each subsequent sewing station
5. Product gets checked at the quality & control station (in line)
6. Product continues to be pieced together at the next subsequent stations
7. Final product gets checked and approved
8. Approved product lands at the unloading station
9. The empty hanger returns to the loading station.

10. Components of Unit Production System:
UPS consists of different types of element, such as:
1.Computer with Software
2.Hanger with Microchips
1. Overhead Conveyor with solid and strong structure

11. Components of Unit Production System:
4.Easy Push Button
5.LCD Control Panel
6.LED Screen

12. 1.Modular Production System:
1.Modular Production System involves a group of 4-17 people who set their own standards and work
together to produce a finished garments. They work as a team or module and each team member
works on more than one operation. In this system operator helps each other to finish the garments
quickly. The team is fully responsible for the production and quality.
2.This MPS system Also popular as a cellular garments Manufacturing or Toyota Sewing
System(TSS)

13. Features of Modular Production System:
• Usually U-shaped layout with more workplace than operator.
• Workflow is sequential.
• WIP is less and productivity is high in this production system.
• Required multi skilled worker and a smaller set of machine to produce finished garments.
Advantages: Disadvantages:
1.MPS leads to cost savings.
2.This system is highly flexible with
style change.
3.Better line balancing.
4.Lower WIP.
5.Enables fast throughout time.
6.Required less floor space
7.Improved quality of product.
1.High capital investment is needed in
initial training workers to deal with several
task at one station.
2.Operators can't develop the rhythm and
the pace of high performance.
3.Depends on the team for whole
production.

14. One piece flow:
• Achieving one-piece flow helps manufacturers achieve true just-in-
time manufacturing. That is, the right parts can be made available
when they are needed in the quantity they are needed.
• one-piece flow means that parts are moved through operations from
step to step with no work-in-process (WIP) in between either one
piece at a time or a small batch at a time.
• This system works best in combination with a cellular layout in
which all necessary equipment is located within a cell in the
sequence in which it is used.

15. One piece flowchart:
Let us begin by stepping back and attempting to
understand the concept of “connected flow." To be
good candidates for one-piece flow, we must have the
following conditions:
1.Processes must be able to consistently produce good
product.
2.If there are many quality issues, one-piece flow is
impossible.
3.Process times must be repeatable as well. If there is
much variation, one-piece flow is impossible.
4.Equipment must have very high (near 100 percent)
uptime. Equipment must always be available to run.
•

16. Price Rate Pay system:
• A piece-rate pay system means that the worker is paid per unit of creation.
Whether the "unit of creation" is a clay pot or a piece of writing, a person is paid
by individual output, no matter how long it takes. This way, you can determine if
this is a system you're willing to work with

17. Gantt Chart:
• Definition : A " Gantt Chart" is a useful graphical tools
which show activities or tasks performed against time. It is
also known as visual presentation of a project where the
activities are broken down and displayed on a chart which
make easy to understand and interpret.

18. Characteristics of Gantt Chart:
• The bar in each row identifies the corresponding task.
• The horizontal position of the bar identifies start and end times of the task.
• Bar length represents the duration of the task.
• Task duration can be compared easily.
• Good for allocating resources and re-scheduling.
• Precedence relationships can be represented using arrows.
• Critical activities are usually highlighted.
• Slack time are represented using bars with doted lines.
• The bar of each activity begins at the activity earliest start time.
• The bar of each activity ends at the activity latest finish time.

19. Advantages and disadvantages of Gantt Chart :
Advantages Disadvantages:
1.Tools for representing the project
schedule.
2.Easy to create.
3.Easy for stakeholders and project teams
to understand the work schedule.
4.Enhances team productivity
1.It is not easy to see all the activities in a
complex project.
2.It can be very time consuming in large
and complex project.
3.Without software, it is not possible to
assign resources to tasks.

20. Gantt chart:
Information on Gantt Chart:
• Activities or tasks.
• Milestones.
• Time frame.
• Data date.
• Actual progress.

21. Project management software:
There are some number of project management software tools which is
available to help in the planning and control in large software development
projects. Such as
 MS Project is a CASE software tool for Project Management
 This software is available in the main computer room in CSIT
Most of the tools include functions to use for plan, schedule and
control, but decision-making still has to be done by the project
manager.
Project management is mainly used for decision making purpose.it is easy
to use and understand for project manager.

22. Benefits of using project management software:
1. Effortless project planning
2. Balanced resource management
3. Improve team collaboration
4. Real time project budget management
5. Solid up-to-the-minute reporting
6. Effective internal and external communication
7. Enhanced customer satisfaction
8. Calculate project schedule

23. Limitation of project management software:
1. loss of resources
2. scheduling problem
3. security issues and interpersonal conflicts
4. Project management software may complicate simple projects
5. Execution issues when relying on automated alerts

24. Conclusion:
The choice of best apparel production system will depend on the product
and policies of the company and on the capacities of manpower. Where
style changes are frequent and lot sizes small, it may be advantageous to
use skilled labor who can make whole garment and use one of the whole
garment system. As the lot size increases it is advisable to use section
production system.
One of the aims of any production system is to make total production time as
minimum as possible. This automatically reduces inventory cost to a minimum.
Sub-assembly system provides many opportunities to economies on temporary
storage and transportation space and time. No definite answer can be given as to
which is the best, as it depends on garment style, specifications, machinery and
manpower and manufacturing policies

25. Thank you