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in Apparel Production
The garment production systems are a combination of production processes, materials handling,
personnel and equipment that direct workflow and produce finished garments. It is a system that
depicts how the two-dimensional fabric is transformed into a three-dimensional garment in a
manufacturing system. The names of the production systems are based on the various factors like
utilization of a number of machines to assemble a garment, layout of machines, total number of
operators involved to produce a garment and number of pieces moving in a production line during
the production of a garment.
Each garment production system needs a suitable management philosophy, materials handling
procedures, plant layout for garments spreading and worker training. The garment industry could
combine various production systems to achieve their specific garments’ production needs like
utilizing only one production system or a combination of different systems for one product style.
Designing production system ensures the coordination of various production activities. There is
no particular production system that is universally accepted, yet there are different types of
production systems followed by different organizations as discussed in the following section.
Processing time + Transportation time + Temporary storage time + Inspection time = Total
Production Time.
Processing time is the sum total of working time of all operations involved in manufacturing a
garment. Transportation time involves the time taken to transport semi finished or finished
garments from one department to another or from one operation/machine to another. Temporary
storage time is the time during which the garment/bundle is idle as it waits for the next operation
or for completion of certain parts. Inspection time is time taken for inspecting semi finished
garments for any defects during manufacturing or inspecting fully finished garments before
packing.
In the apparel industry, the most commonly used production systems are make through, modular
production and assembly line production systems.
Low productivity
High labor cost
It necessitates an experienced operator for assembling
This system is limited to couture and sample making
Group system - Section or Process system:
This is a development of the individual system, with the difference that the operators specialize
in one major component and sew it from beginning to end. For example, an operator specializing
in backs would assemble the back and yoke, label attaching, etc., and performs all the operations
required to finish that particular component.
The sewing room would have a number of sections, each containing multi-talented operators
capable of performing all the operations required for a specific component. The sections shown
in Figure-1 are built according to the average garment produced, and include:
Collar preparation
Sleeve preparation
Front preparation
Back preparation
Assembling operations (closing, setting collars and sleeves, etc.)
Finishing operations (buttonholes, blind-stitching, etc.)
The departmental whole garment system is also used by custom wholesale manufacturers as well
as high price or better dress manufacturers. In the departmental whole garment system one
individual does all the work with the equipment allocated to a department. For example on
person does all the cutting work in cutting department, second person does all the sewing work
in sewing department, third person does the pressing and packing work. The workers in this
system may use more than one equipment to complete his/her job.
The bundled cut garment pieces are moved successively from one job to another job.
One bundle comprises all cut components that are necessary to finish the complete
garment.
Bundle tickets contain a master list of jobs for the particular garment style and
corresponding coupons for each job.
A ticket number will be allotted to each bundle which represents style, size and shade
of the garment.
The two main types of assembly line production system followed in the industries are:
The bundle system of apparel production consists of garment parts needed to complete a specific
operation or garment component. Bundles of garments are assembled in the cutting room where
cut parts are matched up with corresponding parts and bundle tickets. The bundles are moved to
the sewing room and given to the garment operator who is scheduled to complete the operation.
PBS is a variation to the bundle system. The main characteristics of the systems are one worker
with a single skill at a single operation, no interaction between operations, piece rate
compensation, maximization of productivity of individual operators, need for extra spaces for
material storage, straight lined equipment layout, and manual material movement in large
batches. The system helps operators to make more units of garments at faster speeds, with high
productivity but with more quality problems. To stabilize the workflow, higher levels of WIP
add to production costs, not value, and lead to longer lead times. In these systems, the difference
between actual run time and total manufacturing throughput time is significant. The success of
PBS depends on how the production system is set up and used in a plant.
Assume if one operation has a SAM of 1.7 minutes, then all the other operations in the particular
production line should have the same, or closer SAM value. Balancing of standard time for each
operator could result in irrational combinations of whole or part operations which could
minimise the efficiency of individual operators. The layout of a synchro-system for the
manufacture of a full sleeve shirt is shown in Figure-2.
Figure-2: Layout of a synchro-system for the manufacture of a full sleeve shirt
PBS Synchro straight line system:
The PBS synchro system is not a flexible system and liable to frequent breakdown of machines
and more absenteeism. The standby machines and operators should be made available to avoid
bottleneck processes every time. Further, this system needs an adequate quantity of similar styles
of garments for continuous operation of the line.
Though this production system has been in use for several years, major progress was made when
computers were utilized for production planning, production controlling and regulating the
work flow in the production line.
All the cut panels for one garment are loaded into a carrier at a workstation specially
designed for this specific job. The carrier is divided into several sections, each having a
quick-release clamplike system to avoid falling out of cut panels during transportation
through the system.
When a particular batch of cut panels of the garments has been fixed into carriers, they
are fed past an electronic device. This device counts and records the number of the carrier
and addresses it to its first destination.
The loaded carriers are then moved onto the main powered line, which is circulated
between the rows of machines continually. Each workstation is connected to the mainline by
means of junctions, which open automatically if the work on a particular carrier is addressed
to that particular work station.
The carrier is moving toward the left side of the operator and waits along with the other
carriers in the work station. When the operator has completed the particular work on one
carrier, he or she has to press a push button, which is positioned at the side of the sewing
machine, to activate a mechanism that transports the carrier back to the main line so that
another carrier will be fed automatically to take its place.
A data collection system records when the carrier left the station and then it is
addressed to its next destination.
Figure -3: Work station and carrier arrangement in the UPS system
The work station and carrier arrangement in the UPS system is shown in Figure -3.
1. Processing time: It is the total working time of all the processes involved in assembling
a garment.
2. Transportation time: It is the total time consumed for movement of semi finished or
finished garments from one workstation or department to another.
3. Waiting time of unfinished garments: It is the idle time of a work bundle when it waits
for the next operation.
4. Inspection time: It is time taken for in-process inspection of semi finished garments or
final inspection of finished garments before packing.
The choice of best apparel production system will depend on the product and policies of the
company and on the capacities of manpower. The main goal of all the production systems is to
decrease the total production time which leads to reduction in inventory cost. The appropriate
selection of a suitable garment production system for an industry is influenced by the product
style and policies of the industry and on the labour capacity. The cost of inventory decides the
choice of a production system in most circumstances in an apparel industry. When material,
labor, space and interest costs are high, a synchronized subassembly system, which gives the
minimum possible in-process inventory, is more suitable.