Garment production system

A garment industry can choose any production system. It depends on the asset he has and the management policy.

1. Presented By Md. Shamsuzzaman B.Sc. (WUB), M.Sc. (BUTEX) Lecturer, Department of Textile Engineering World University of Bangladesh Contact: [phone] Email: [email protected] WORLD UNIVERSITY OF BANGLADESH Department of Textile Engineering 6/22/2020 Slide Prepared by- Md. Shamsuzzaman Garment Production Systems Course Name: Apparel Engineering IV Course Code: AE 1101

2. Overview of the Class 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 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 2 of 22

3. Definition 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 3 of 22 A garment production system is a way how fabric is being converted into garment in a manufacturing system

4. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 4 of 22 The objectives of garment production systems Examine the features of different kinds of garment production systems Compare and contrast the different production systems Assess and critically relate the merits and demerits of utilization of different production systems in various circumstances

5. Factors of garment production system 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 5 of 22 Company affordability Equipment that directly involved with workflow Items of finished products Machine or floor layout Management philosophy Materials handling system Personnel training Production processes

6. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 6 of 22 How Production systems are named? Number of machines used in layout Total number of operators involved Number of pieces moving in a line during making a garment.

7. Principles of choosing a production system 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 7 of 22

8. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 8 of 22 Some popular Garment Production Systems Make Through System/ Individual Production system Progressive Bundle System / Batch System Section or Process System - Group System  Modular Production System One Piece Flow System UPS -Unit Production system Piece Rate Production System Straight-line or ' Synchro ' System

9. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 9 of 22 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. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 10 of 22 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. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 11 of 22 Progressive Bundle System / Batch System Disadvantages: - High investment on machine cost. - Short run production is not adaptable. - High level of WIP extends throughput time. - Complicated management skill is required 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.

12. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 12 of 22 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. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 13 of 22 Advantages T he 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.  Section or Process System - Group System  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. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 14 of 22 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. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 15 of 22 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. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 16 of 22 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. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 17 of 22 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. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 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.

19. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 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

20. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 20 Straight-line or 'Synchro' System This system is based on a synchronized flow of work 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

21. Further Reading 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 21 of 22 https://www.onlineclothingstudy.com/2011/09/garment-production-systems.html https://clothingindustry.blogspot.com/2017/11/production-system-garment-industry.html

22. 6/22/2020 Slide Prepared by- Md. Shamsuzzaman 22 of 22 The End