Garment Production System

1. Garment Production
Systems

2. 1. Definition
2. Objectives of production system
3. Factors garment production systems
4. How Production systems are named
5. Principles of choosing a production system
6. Popular Garments Production

3. A garment production system is a way how
fabric is being converted into garment in a
manufacturing system

4. The objectives of garment production systems
1. Examine the features of different kinds of garment production systems
2. Compare and contrast the different production systems
3. Assess and critically relate the merits and demerits of utilization of
different production systems in various circumstances

5. i. Company affordability
ii. Equipment that directly involved with workflow
iii. Items of finished products
iv. Machine or floor layout
v. Management philosophy
vi. Materials handling system
vii. Personnel training
viii. Production processes

6. How Production systems are named?
1. Number of machines used in layout
2. Total number of operators involved
3. Number of pieces moving in a line during making a
garment.

8. Some popular Garment Production Systems
1. Make Through System/ Individual Production system
2. Progressive Bundle System / Batch System
3. Section or Process System - Group System
4. Modular Production System
5. One Piece Flow System
6. UPS -Unit Production system
7. Piece Rate Production System
8. Straight-line or 'Synchro' System

9. Make Through System/ Individual Production system
 It is traditional method of production whereby one operator assembles
the entire garment, example tailoring
 The tailor even makes pattern (use ready-made pattern), cuts fabric and
does finishing of the garment
 The system requires a highly skilled and versatile person
 Suitable to produce a large varieties of garment with small quantities

10. Progressive Bundle System / Batch System
 Also called material handling system
 Garment parts are moved from one operation to another sequentially and in bundle form
 Each operator receives a bundle, does his work, reties the bundle and passes it to the next
operator
 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
Application
It is used in shirt factories,
jeans factories, jacket
factories, etc.

11. Progressive Bundle System / Batch System
Advantages:
- The line is easier to balance and control.
- Uniform quality can be ensured by in-process control.
- Semi-skilled labour requires less training time and cost.
- Individual performances can be monitored by incentives.
Disadvantages:
- High investment on machine cost.
- Short run production is not adaptable.
- High level of WIP extends throughput time.
- Complicated management skill is required

12. Section or Process System - Group System
 This is a development of the making through system and similar to the
Progressive Bundle System
 The operations are divided in sub-section
º Pre-assembling (the preparation of small parts)
º Front making
º Back making
º Main assembly (closing, setting collars and sleeves, etc)
º Lining making
º Setting linings
º Finishing operations (buttonholes, blind-stitching, etc)

13. Section or Process System - Group System
Advantages
 The labor of all levels, ie, semi skilled, skilled, trainee can be used in this system
 This system is very efficient for producing a variety of styles in reasonable
quantities.
 Automation and specialization can be done.
 Absenteeism and machine breakdown problems will not cause serious problems.
Disadvantage
 Quality of the garment can be deteriorated due to operators used from all level
 Group of people involved in each section which increases the inventory cost.
 As this is not a bundling system, there are more chances to mix up of lost,
shade variation, sizes, so quality and production will be affected.

14. 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.
 Team is fully responsible for quality and production and team performance is
evaluated

15. Modular Production System
Advantages
- Lower level of WIP 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
Applications
- Fashioned garments with quick response.
-Orders with low volume and frequent
changes.
- Company with mutual trust between
management and
operators
Disadvantages
- Training time and cost is increased
- specialized equipment is poorly utilized
-Operators cannot develop the rhythm and
pace of high performance
-Individual effort is difficult to recognized
within the group

16. One Piece Flow System
This system works best with the components of a single piece instead of
bundle/ multiple pieces
Sewing machine can be laid in straight line/modular line
Operator receive one piece from back and move one piece to his next
Benefits of One-piece-Flow system are less through put time, Less WIP in the
line.

17. UPS -Unit Production system
 The unit of production is a single garment and not bundles
 The garment components are automatically transported from workstation
to work station according to a pre-determined sequence.
 The work stations are so constructed that the components are presented
as close as possible to the operator's left hand in order to reduce the
amount of movement required to grasp and position and component to be
sewn.

18. Disadvantages
 Unit production system requires high
investments.
 The payback period of the investment
takes long time.
 Proper planning is required to be
effective
 Quick Response Sewing System.
UPS -Unit Production system
Advantages
 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 systems
automatically balance the work
between stations.
 Up to 40 styles can be produced
simultaneously on one system.
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19. Piece Rate Production System
Piece 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.
Workers are paid on the basis of output produced by him; time is not
considerable
Wages = No. of unit produced x Rate per unit
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20. Straight-line or 'Synchro' System
 This system is based
synchronized flow of work
on a
through
each stage of producing a garment
 Time-synchronization is the
most
important factor of this system
 If a operator SAM is 1.5 minute then
all other operators SAM should be
same
 Unbalancing of layout can cause
bottleneck
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21. The End