This document discusses three garment production systems: the progressive bundle system (PBS), unit production system (UPS), and modular production system (MPS). PBS is the most traditional system, where bundles of garment parts move from operation to operation. UPS uses overhead carriers to move completed garment parts between stations. MPS organizes workers into teams responsible for entire garment assembly. Each system has advantages like quality control and flexibility, and disadvantages like costs or planning requirements. The document was authored by MD Siyam Hossain of Bangladesh Institute of Business & Technology to explain these three common apparel manufacturing approaches.

1. GARMENT PRODUCTION SYSTEM.
BY:
MD Siyam Hossain.
Bangladesh Institute of Business & Technology.
AMT 1st
Batch.

2. Garment Production System
 In simple a ‘garment production system’ is a way how
fabric is being converted into garment in a
manufacturing system.
 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:
I. Progressive Bundle System
II. Unit Production System
III.Modular Production System
MD Siyam Hossain

3. 1. Progressive Bundle System
(PBS)
 Also Called Material Handling System.
 As name implies the bundle of garment parts move from
operation to operation.
 Traditional Production system.
 Widely used by apparel manufacturers for several
decades and still today.
 80% apparel manufacturers use the Bundle system
(PBS).
MD Siyam Hossain

4. PBS Workflow
 Bundles consist of garment parts needed to complete a
specific operation (e.g an operation bundle for pocket
setting might include shirt fronts and pockets to b
stitched together.
 Some firms operate with a standard bundle size, while
other vary bundle sizes acc. to size of pieces in bundle
and operation to b completed.
 Bundles are assembled in the cutting room, where cut
parts are matched up with corresponding parts and
bundle tickets.
 Workers (labour) transport and move Bundles of cut
parts to sewing room via trollies.
 Operator scheduled to complete the operation and
perform same operation on all pieces in the bundle, retie
the bundle, remove Bundle ticket and move bundle for
next operation.
MD Siyam Hossain

5. Progressive Bundle System
MD Siyam Hossain

6. Advantages of PBS
 Labor of all levels ie unskilled, skilled, semi skilled labors
are involved. Small simple operations.
 Quantity of each operation is checked during every
single operation thus quality is good.
 Due to bundle system, less chance of mixing up of
parts…thus less confusion.
 Bundle tracking is possible, so identifying and solving
problems become easy.
 Effective production control system and Quality control
system.
MD Siyam Hossain

7. Dis-advantages of PBS
 Time Consuming due to assembling, moving and un-
tieing of bundles.
 More labor…More labor cost.
 Needs efficient supervisor.
 Labor absentiees can effect production due to
incompletion of contracts.
 Variety of styles and less quantity is not effective in this
system.
 Proper planning is required for each style, each batch.
 Improper planning causes labour turnover, poor quality,
less production, etc.

8. 2. 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.
 In UPS, there are hangers. One hanger have multiple
clips containing all parts of the single garment.
 All parts for the single garment are advanced through
stitching line together by means of hanging carrier that
moves along an overhead conveyor.
 Hanging carrier can be moved manually by the operator
using button after completion of single operation or By
computerized system that move the conveyor after a
specific fed throughput time.
MD Siyam Hossain

9. UPS Workflow
 Load all the pieces of single garment in a product
carrier.
 The product carrier with the pieces will be routed
through the different operation steps.
 At every machine/operation the patented chain will
position the product ideally.
 Completed the product arrives to an unloading
station. The empty product carrier returns to the
loading station.
MD Siyam Hossain

10. Unit Production System
MD Siyam Hossain

11. Advantages of UPS
 Bundle Handling completely eliminated.
 The time involved in the pick-up and disposal is
reduced to minimum.
 Output is automatically recorded, eliminates the
operator to register the work.
 The computerized system automatically balance
the work between stations.
 Improved lead times-less work in process.
 Improved space utilization (more machines can be
adjusted)
MD Siyam Hossain

12. Advantages of UPS (Cont.)
 Increased Productivity.
 Throughput time can be drastically
reduced.
 Indirect labor costs are reduced (by
elimination of bundle handling and
requiring fewer supervisors)
 Improved production and quality.
MD Siyam Hossain

13. Dis-advantages of UPS
 Unit Production system requires high
investment.
 Proper planning is required to be effective.
 Highly expensive-buying equipment and
cost of installing.
 Specialized training for the system.
MD Siyam Hossain

14. 3. Modular Production System
 A Modular Production System is a contained,
manageable work unit that includes an empowered work
team, equipment and work to be executed.
 The number of teams in a plant varies with the size and
needs of the firm and product line.
 Usually there are 4-15 labors in one team depending
upon the type of garment to be stitched and skills of
labor.
 Teams may be used to perform all the operations (whole
garment production) or certain portion of assembly
operations.
 Team is responsible fro maintaining a smooth work flow,
meeting production goals, quality level.
MD Siyam Hossain

15. Modular Production System
 Team members develop an interdependency to
improve the process and accomplish their goals.
 A worker in a team can perform Multiple functions
depending upon his skills (Multi-skills).
MD Siyam Hossain

16. Modular Production System
MD Siyam Hossain

17. Advantages of MPS
1) High Flexibility.
2) Fast throughput times.
3) Low wastages.
4) Reduced absenteeism.
5) Empowered employees.
6) Improved Quality.
MD Siyam Hossain

18. Dis-advantages of MPS
 A high capital investment in equipment.
 High investment in initial training.
 No compatibility between team members can
cause problems thus loss in production…
 Dependency on the Team for whole Production.
MD Siyam Hossain

19. 11/10/16
Thank You Everyone
MD Siyam Hossain