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