The document describes three garment production systems: 1) Progressive Bundle System, where bundles of garment parts move sequentially between operations; 2) Unit Production System, which uses an overhead transport system to move individual garments between automated work stations; and 3) Modular Production System, where small teams of multi-skilled operators work together to complete full garments. The Modular Production System allows for flexibility, quick response times, and improved quality and teamwork compared to traditional bundle systems. It involves cross-trained workers organized into modules to collaboratively produce garments from start to finish.

1. Garments Production System
& MPS
Jamuna Apparels Ltd.
Prepared By: Mahmudul Hasan Ferdous
Sr. IE Officer
Jamuna Apparels Ltd.

2. Content

3. Production System
• 1. Progressive Bundle System.
• 2. Unit Production System
• 3. Modular Garments Production System

4. 1. Progressive Bundle System
• As the name implies the bundles of garment parts are moved sequentially
from operation to operation. This system, often referred to as the traditional
production system, has been widely used by apparel manufacturers for
several decades and even today

6. 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.
• The garments are gradually assembled as they move through successive sub-assembly and main assembly operations in
bundle form.
• 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.
• The use of the system decrease as firms seeks more flexibility.
• 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.
• This system is the most widely used system in the garment industry today.

7. Advantages Progressive Bundle System
• This system may allow better utilization of specialized machines, as output
from one special purpose automated machine may be able to supply several
operators for the next operation.
• Small bundles allow faster throughput unless there are bottlenecks and
extensive waiting between operations.

8. Disadvantages Progressive Bundle System
• Slow processing, absenteeism, and equipment failure may also cause major
bottlenecks within the system.
• Large quantities of work in process. This may lead to longer throughput
time, poor quality concealed by bundles.
• Large inventory, extra handling and difficulty in controlling inventory

9. 2. Unit Production System
• A unit production system (UPS) is a type of line layout that uses an overhead
transporter system to move garment components from work station to work
station for assembly. All the parts for a single garment are advanced through
the production line together by means of a hanging carrier that travels along
an overhead conveyor.

11. Features of a Unit Production System
• This system concerned with a single garment and not bundles.
• This system is entirely computer controlled.
• It uses an overhead transportation system that automatically routes and deliver the cut pieces to each sewing station.
• Even if one station does not work, the whole system still works normally.
• It has been ergonomically designed to reduce the amount of handling of the garment.
• This system is capable for rework easily. Because each garment is tracked within the system and any problems to
with quality control can be traced back automatically to the operator to be corrected.
• This system also records all data in each workstation within the line and compute them for Management Planning &
Control.
• Sewing operators concentrate on sewing without worrying where workpieces are coming from and should go to.
• It is possible to produce multiple designs, colors and sizes at the same time in the same production line.

12. Operational Principles of Unit Production
System
• An operator set the process in the control station.
• Worker loads the cut pieces in a hanger from the loading station
• The hanger routes to the next workstation automatically according to the predetermined
process in the control station.
• Product is put together at every stage at each subsequent sewing station
• Product gets checked at the quality & control station (in line)
• Product continues to be pieced together at the next subsequent stations
• Final product gets checked and approved
• Approved product lands at the unloading station
• The empty hanger returns to the loading station

13. Advantages of Unit Production System
• Bundle handling completely eliminated.
• Decreased work in process (WIP), improved space utilization, and increased productivity are but a few
of the systems benefits.
• Improve the machine utilization, reduce the handling and increase the moving time of needles.
Generate real-time performance report.
• Improved lead timeless work in process.
• Better handling of garment without touching the floor.
• No chance of serial and sequence mistakes.
• Output is automatically recorded, eliminates the operator to register the work.
• Labor costs reduced by elimination of bundle handling and employee attendance improved.
• Less rejection and automatic counting of the finished product.

14. Disadvantages of Unit Production System
• Proper planning is required to be effective.
• The payback period of the investment takes a long time.
• Variety of styles & less quantity are not effective in this system.
• Shuttle operators and utility operators needed in every batch to balance the
line effectively.
• Proper maintenance of equipment and machinery is needed.

15. Modular Production System
• Modular production system involves a group of 4-17 people who set their own
standards and work together to produce a finished garment. They work as a team or
module and each team member works on more than one operation.
• In this system, operators help each other to finish the garment quickly and the team
is fully responsible for the production and quality.
• The number of teams in a plant varies with the need of the industry, size of the
industry and product line in garments.
• This system MPS is the perfect solution for the apparel manufacturer where quick
response is needed. This system is also popular as a Cellular Garment
Manufacturing, flexible workgroups or Toyota Sewing System (TSS).

16. Modular Production System
• Used successfully in Japan, Europe and US since 90’s
• Groups operators into teams or modules of 5-17 crossed trained operators.
The team work on one garment at a time with operators standing at their
work stations and rotate to different machines as they work. It can assemble
an entire garment or sub-assembly of more complex product. Arrangement
follows a logical operation breakdown.
• The team inspects their own work, besides inspiring teamwork and
improving morale, it enhances quality and reduces worker turnover.

17. Example of Layout

18. Example of Layout

19. Features of a Modular Production System
• Usually U-shaped layout with more workplaces than operators.
• Operators move between operations within module whenever extra WIP exists.
• Required multiskilled workers and a small set of machines to produce a finished garment.
• Each operator performs approximately 2-4 operations, depending on the product.
Workflow is sequential.
• WIP is less and productivity is high in this production system
• The operators stand /sit at their stations and rotate in different sewing machines to complete the
operations.
• Time spent per garment is also little.

20. Advantages of Modular Production System
• MPS leads to cost savings.
• The system is highly flexible with style changes and permits better line balancing.
• Enables fast throughput time, lower WIP, and small batch size can be achieved.
• Peer pressure encourages a team spirit and discourages absenteeism.
• Productivity of human labour
• Reducing supplies of unfinished production
• Required less floor space
• Improved quality of the product.

21. Advantages of Modular Production System
(Cont.)
• 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 4-17 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 for maintaining a smooth work flow, meeting production goals, quality level.
• 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)

22. Advantages of Modular Production System
(Cont.)
• Lower level of WIP frees up capital tied up and floor space.
• Fast throughput time enables quick response and prompt delivery.
• Quality becomes a team responsibility and monitored at source.
• Peer pressure encourages a team spirit and discourages absenteeism.
• The system is highly flexible with style changes.

23. U-Shaped Cell
• A U-shaped cell is exactly what it
sounds like—a work area that is
organized in the shape of a ‘U’.
• The U-shaped cell allows an
operator to finish her work in
virtually the same location that
she started, eliminating the waste
of walking back from the end of
a line to the start.

24. U-Shaped Cell
• This configuration is most effective when one operator is moving through
several stations. The flow in a U shaped cell should be set up to go
counterclockwise. Most people are right-handed, so moving
counterclockwise keeps their dominant hand where the work is.
• The U shaped cell should be set up to allow two operators to work back to
back, even if there is not currently demand for it. Often, they will need help,
or people may need to be added to the U-shaped cell later when the
workload does increase.
• A U-shaped cell also supports communication. In a long, straight line,
operators may be far away from each other. In a U shaped cell, they are in
close proximity and can easily ask questions and problem solve

25. Example of U-Shaped Cell

26. Example of U-Shaped Cell

27. Disadvantages of Modular Production
System
• High capital investment is needed in initial training workers to deal with several
tasks at one station.
• It requires considerable changes in management philosophy.
• This system requires a higher degree of communication and cooperation among
operators, mechanics, and supervisors.
• Operators cannot develop the rhythm and pace of high performance.
• No harmony between team members can cause problems, thus loss in production.
• Depend on the Team for whole Production.

28. Applications
• Fashioned garments with quick response.
• Orders with low volume and frequent changes.
• Company with mutual trust between management and operators

29. Video of MPS

30. Thanks